Testing and Adjusting

Usage:

Transmission Hydraulic Controls

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In all transmission hydraulic tests, do the steps that follow:

1. Lift the body and install the two pins at the rear of the truck.
2. Disconnect the hoist control linkage at the hydraulic tank.
3. Disconnet the rear drive shaft from the rear of the transmission.
4. Let only approved personnel on the machine. Keep other personnel off the machine.

PINS INSTALLED IN BODY OF TRUCK

HOIST CONTROL LINKAGE DISCONNECTED AT THE HYDRAULIC TANK

NOTE: All tests and adjustments must be made with the oil in the hydraulic control system at the temperature of normal operation. Be sure the linkage adjustments are correct before the tests and adjustments are made.

Method To Control Engine Speed During Tests

6V4160 Transmission Hydraulic Test Group3B7740 Nipple-1/4" NPT × 6".1/4" NPT Internal Tee.1/4" NPT × 1.25" Nipples (four).7S8881 Quick-Connect Socket Assembly (three).7S8889 Quick-Connect Plug (1/4"-18 NPT Female) (two).Hose Groups (two). Consists of:7S8890 Nipple (two).7S8894 Hose Assembly (two).7S8895 Socket Assembly (two).4L4454 Regulator.5P2160 Engine Horsepower Meter Arrangement or 1P5500 Portable Phototach Group.

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Before any tests are made, disconnect the rear drive shaft from the transmission.

1. Remove plug (73) for air supply and disconnect hose (74) for governor supply from the cab.

RIGHT SIDE OF CAB
73. Plug for air supply. 74. Hose for governor supply.

2. Install nipple (78) in place of plug (73) and install tee (80) on nipple (78).

3. Install a nipple (1.25" long) in each end of tee (80).

4. Install a socket (79) on each nipple (1.25" long).

NOTE: One of sockets (79) is used to activate the hold valve, if needed.

5. Install plug (81) in the end of hose (74).

6. Install a nipple (1.25" long) in each end of regulator (82).

7. Install socket (79) and plug (81) to the nipples as shown.

CONNECTION TO THE AIR SUPPLY AND GOVERNOR
74. Hose for governor supply. 75. Hose group from the air supply to the regulator. 76. Hose group for operation of the hold valve. 77. Hose group from the governor to the regulator. 78. Nipple (6" long). 79. Socket. 80. Tee. 81. Plug (female).

8. Install hose group (75) from the air supply to regulator (82).

9. Install hose group (77) from hose (74) to regulator (82).

NOTE: Hose group (76) is for the operation of the hold valve, if needed.

CONNECTION TO THE REGULATOR
75. Hose group from the air supply to the regulator. 77. Hose group from the governor to the regulator. 79. Socket. 81. Plug (female). 82. Regulator.

10. Use the regulator to control the speed of the engine. Use the Engine Horsepower Meter Arrangement or Portable Phototach Group to measure engine speed. This can be done at the transmission location to make transmission tests and adjustments easier.

Method To Control The Transmission During Tests

1P3550 or 5P6590 Wiring Tester Group.FT1067 657B Eight-Speed Transmission Harness Assembly.

OPERATION OF THE TRANSMISSION
83. Eight-speed transmission harness assembly. 84. Harness for 16 pins. 85. Jumper. 86. Sync harness.

1. Turn the machine disconnect switch to OFF.

2. Disconnect the chassis harness from the slave switch and both solenoids.

3. Connect eight-speed transmission harness assembly (83) as shown to the slave switch and both solenoids.

4. Connect harness (84) for 16 pins to the tester and also to eight-speed transmission harness assembly (83).

5. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

6. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

7. To connect jumper (85), use Step a. if the jumper has pins and Step b. if the jumper has sockets.

a. Connect one end of jumper (85) to the negative terminal of the tester. Connect the other end to socket B of sync harness (86).

b. Connect one end of jumper (85) to the ground clip of the black battery lead wire. Connect the other end to pin M of harness (84) for 16 pins.

8. On the tester, put the LAMPS CONTROL switch ON, the CONTINUITY TEST switch OFF, and the SELECTOR switch to position "C" (neutral).

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON, the POWER switch to EXTERNAL, the JUMPER wire across the battery power bulb and the SELECTOR switch to position "C" (neutral).

9. Turn the machine disconnect switch to ON and start the engine.

10. Shifts of the transmission can now be controlled by the SELECTOR switch of the tester. Use the chart to move the transmission through all speeds. A lamp will come ON at each position of the SELECTOR switch.

Location Of Pressure Taps

K. Pressure tap for transmission lubrication. L. P1 pressure tap.

M. Pressure tap for transmission pump. P. Pressure tap for torque converter inlet.

P. Pressure tap for torque converter inlet. R. Pressure tap for torque converter outlet.

87. Transmission selector shaft. 88. Wires for the upshift and downshift solenoids. S. Pressure tap for reduction valve (43).

T. Pressure tap for hold valve (12).

U. Pressure tap for air.

AUTOMATIC SHIFT GROUP IN REVERSE (CONVERTER DRIVE)

1. Shift pressure valve.

2. Priority valve.

3. Downshift reduction valve.

4. Line to pressure control valve.

5. Line from transmission oil filter.

6. Manual selector spool.

7. Automatic selector valve.

8. Spool for governor cut-off valve.

9. Governor reduction valve "C".

10. Accumulator for governor reduction valve "B".

11. Shift governor.

12. Hold valve.

13. Governor cut-off valve.

14. Governor reduction valve "A".

15. Hydraulic shift spool.

16. Accumulator group for the governor.

17. Accumulator for governor reduction valve "A".

18. Upshift reduction valve (first to second speed upshift).

19. Governor reduction valve "B".

20. Automatic selector spool (first to second speed shift).

21. Automatic selector spool (sixth to seventh speed shift).

22. Hold slugs (six).

23. Automatic selector spool (second to third speed shift).

24. Automatic selector spool (fifth to sixth speed shift).

25. Upshift reduction valve (second to third, fourth to fifth and sixth to seventh speed upshifts).

26. Upshift reduction valve (third to fourth and fifth to sixth speed upshifts).

27. Automatic selector spool (fourth to fifth speed shift).

28. Automatic selector spool (third to fourth speed shift).

29. Downshift slugs (six).

30. Passage from pressure control valve.

31. Line from governor reduction valve "A".

A. Adjustment screw for all downshift points.

B. Pressure tap governor supply.

C. Pressure tap for governor reduction valve "C".

D. Pressure tap for governor reduction valve "B".

E. Adjustment screw for priority valve.

F. Adjustment screw for upshift point (first to second speed).

G. Pressure tap for governor reduction valve "A".

H. Adjustment screw for upshift points (second to third, fourth to fifth and sixth to seventh speeds).

J. Adjustment screw for upshift points (third to fourth and fifth to sixth speeds).

PRESSURE AND SELECTOR VALVE GROUP IN REVERSE (CONVERTER DRIVE)

4. Line to pressure control valve.

5. Line from transmission oil filter.

30. Passage from pressure control valve.

31. Line from governor reduction valve "A".

32. Passage to transmission lubrication.

33. Pressure control valve.

34. Check valve.

35. Selector valve.

36. Check valve.

37. Flow control valve.

38. Oil filter for transmission.

39. Oil pump for torque converter.

40. Inlet relief valve.

41. Load piston relief valve.

42. Modulation relief valve.

43. Reduction valve.

44. Oil pump for transmission.

45. Selector spools.

46. Sequence and pressure control valve.

47. Upshift solenoid.

48. Downshift solenoid.

49. Load piston.

50. Shift spool.

51. Oil filter for torque converter.

52. Lock-up clutch selector valve.

53. Screen.

54. Oil cooler.

55. Protective valve.

56. Oil pump drive.

57. Torque converter.

58. Load piston for No. 6 clutch.

59. Magnetic screen.

60. Oil filter in hydraulic oil tank.

61. Accumulator group for No. 6 clutch.

62. Shuttle valve.

63. Orifice and check valve.

64. Reservoir in torque converter.

65. Reservoir in transmission.

66. Screen.

67. Brake cooling circuit.

68. Outlet relief valve.

69. Lock-up clutch.

70. Scavenge pump for torque converter.

71. Scavenge pump for transmission.

72. Hydraulic oil tank.

K. Pressure tap for transmission lubrication.

L. P1 pressure tap.

M. Pressure tap for transmission pump.

N. Adjustment screw for lock-up clutch shift points.

P. Pressure tap for torque converter inlet.

R. Pressure tap for torque converter outlet.

Pressure Tests For The Hydraulic Controls

6V4160 Transmission Hydraulic Test Group6V4161 Hydraulic Test Group

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Before you make a check of the hydraulic controls, make sure the rear drive shaft is disconnected from the transmission. See the TRANSMISSION PRESSURE AND ADJUSTMENT CHART.

Reduction Valve (43)

1. Install a 300 psi (2050 kPa) pressure gauge at pressure tap (S).

2. Run the engine at high and low idle rpm in NEUTRAL. The pressure at pressure tap (S) must be 160 ± 5 psi (1100 ± 35 kPa).

3. Make shifts to REVERSE and to all speeds forward. The pressure must be the same in all speeds.

NOTE: To change pressure, add or remove spacers (89) for reduction valve (43) of sequence and pressure control valve (46).

SEQUENCE AND PRESSURE CONTROL VALVE
43. Reduction valve. 89. Spacers.

Priority Valve (2)

1. Install a 1000 psi (6900 kPa) pressure gauge at pressure tap (M).

2. Run the engine at high idle rpm in NEUTRAL. The pressure at pressure tap (M) must be 480 ± 10 psi (3335 ± 70 kPa).

3. Make shifts to REVERSE and to all speeds forward. The pressure at pressure tap (M) must be the same in all speeds.

4. Run the engine at low idle rpm in NEUTRAL. The pressure at pressure tap (M) must be a minimum of 460 psi (3170 kPa).

5. Make shifts to REVERSE and to all speeds forward. The pressure at pressure tap (M) must be the same in all speeds.

NOTE: To change pressure, turn adjustment screw (E) for priority valve (2).

Load Piston Relief Valve (41)

1. Install a 600 psi (4150 kPa) pressure gauge at P1 pressure tap (L).

2. Run the engine at high idle rpm in NEUTRAL. The pressure at P1 pressure tap (L) must be 300 ± 15 psi (2050 ± 105 kPa).

3. Make a shift to SECOND through SEVENTH speeds. The pressure at P1 pressure tap (L) must be the same in all speeds.

4. Run the engine at low idle rpm in NEUTRAL. The pressure at P1 pressure tap (L) must be a minimum of 275 psi (1900 kPa).

5. Make a shift to SECOND through SEVENTH speeds. The pressure at P1 pressure tap (L) must be the same in all speeds.

NOTE: If the pressures ARE NOT the same in SECOND through SEVENTH speeds, there is a problem in a clutch (planetary) section of the transmission. If the pressures ARE the same in SECOND through SEVENTH speeds, but the pressures are not correct; add or remove spacers (90) for load piston relief valve (41).

Protective Valve (55) and the Primary Setting of Modulation Relief Valve (42)

1. Install a 0 to 100 psi (0 to 690 kPa) pressure gauge at P1 pressure tap (L).

2. Connect a supply of pressure air [70 psi (480 kPa) minimum] to pressure tap (U) for hold valve (12).

3. Install a lever or Vise-Grip pliers on transmission selector shaft (87).

4. Disconnect wires (88) from the upshift and downshift solenoids.

5. Make a shift manually to any speed, except NEUTRAL, and start the engine.

6. If the output shaft of the transmission turns, protective valve (55) is not in operation.

LOCATION OF SPACERS IN PRESSURE CONTROL VALVE
90. Spacers for load piston relief valve. 91. Spacers for modulation relief valve.

7. The pressure at P1 pressure tap (L) must be 45 ± 3 psi (310 ± 20 kPa).

NOTE: If the pressures ARE NOT the same in REVERSE and FIRST speeds, there is a problem in a clutch (planetary) section of the transmission. If the pressures ARE the same in REVERSE and FIRST speeds, but the pressures are not correct; add or remove spacers (91) for modulation relief valve (42).

Modulation Relief Valve (42)

1. Install a 0 to 600 psi (0 to 4150 kPa) pressure gauge at P1 pressure tap (L).

2. Run the engine at high idle rpm in REVERSE and FIRST speeds. The pressure at P1 pressure tap (L) must be 410 ± 15 psi (2820 ± 105 kPa).

3. Run the engine at low idle rpm in REVERSE and FIRST speeds. The pressure at P1 pressure tap (L) must be a minimum of 390 psi (2740 kPa).

NOTE: Do not adjust for maximum P1 pressure in REVERSE and FIRST (converter drive) speeds. Adjust for primary P1 pressure only.

Transmission Lubrication

1. Connect a 0 to 30 psi (0 to 205 kPa) pressure gauge at pressure tap (K).

2. Run the engine at low idle rpm in NEUTRAL. The pressure at pressure tap (K) must be .5 to 5 psi (4 to 35 kPa).

3. Make shifts to REVERSE, and to all speeds forward. The lubrication pressure must be .5 to 5 psi (4 to 35 kPa).

4. Run the engine at high idle rpm in NEUTRAL. The pressure at pressure tap (K) must be 15 to 21 psi (105 to 145 kPa).

5. Make shifts to REVERSE and to all speeds forward. The lubrication pressure must be 15 to 21 psi (105 to 145 kPa).

Inlet Relief Valve (40)

1. Install a 0 to 200 psi (0 to 1380 kPa) pressure gauge at pressure tap (P).

2. Run the engine at high idle rpm in all speeds. The pressure at pressure tap (P) must not be over 135 psi (930 kPa) at any time.

NOTE: Adjustment of inlet relief valve (40) must only be done during a bench test.

LOCATION OF SPACERS FOR INLET AND OUTLET RELIEF VALVES
92. Spacers.

Outlet Relief Valve (68)

NOTE: The pressure setting for outlet relief valve (68) must be done with the torque converter at a stall. See the section, TEST OF THE OPERATION OF THE TORQUE CONVERTER, for this pressure test.

Hold Valve (12)

7S8887 Quick-Connect Plug (1/4"-18 NPT Male).

7S8890 Nipple.7S8894 Hose Assembly.7S8895 Socket Assembly.

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Make sure the rear drive shaft is disconnected from the transmission before this test is made.

CONNECTION TO THE AIR SUPPLY
74. Hose for governor supply. 75. Hose group from the air supply to the regulator. 76. Hose group for operation of the hold valve. 77. Hose group from the governor to the regulator. 78. Nipple (6" long). 79. Socket. 80. Tee. 81. Plug (female).

1. Remove the plug at pressure tap (T).

2. Install plug (93) at pressure tap (T).

3. Install hose group (76) as shown to socket (79) and plug (93).

CONNECTION AT PRESSURE TAP (T)
76. Hose group for operation of the hold valve. 93. Plug (male).

4. Install a lever or Vise-Grip pliers on transmision selector shaft (87).

5. Let the engine run at low idle rpm. Manually shift the transmission through each speed.

NOTE: There is a detented position between first and second speeds.

6. The operation of hold valve (12) is correct if the transmission remains in any speed that is manually selected.

Adjustment Of Transmission Linkage

TRANSMISSION HYDRAULIC CONTROLS (View From Left Side)

7. Automatic selector valve.

15. Hydraulic shift spool.

35. Selector valve.

45. Selector spools (four).

94. Cam.

95. Gear.

NOTE: The timing marks on gear (95) and cam (94) must be in alignment.

DETENT IN THIRD NOTCH
94. Cam (manual). 95. Gear. 96. Detent.

1. Turn cam (94) until detent (96) is in the third notch, as shown. This notch has a "1" on it.

NOTE: The "1" on cam (94) DOES NOT mean first speed. The only function of the third notch is for adjustment purposes. First speed notch is actually the fourth notch of cam (94). Make sure that detent (96) is in the THIRD notch of cam (94).

DETENT IN SIXTH NOTCH
97. Cam (hydraulic). 98. Detent.

2. Adjust the link end of manual selector spool (6) until the opposite end is even with face (W) of automatic selector valve (7).

3. Turn cam (97) until detent (98) is in the third notch. This is the first speed notch and has a "1" on it.

4. Adjust the link end of spools (45) until the opposite ends are even with face (V) of selector valve (35).

SELECTOR VALVE
45. Selector spools. V. Face of selector valve.

AUTOMATIC SELECTOR VALVE
6. Manual selector spool. 15. Hydraulic shift spool. W. Face of automatic selector valve.

5. Turn cam (97) until detent (98) is in the sixth notch, as shown. This notch has a "4" on it.

NOTE: There is a detent position on cam (97), between first and second speed notches, that is not used. Therefore, the "4" on cam (97) DOES NOT mean fourth speed. The sixth notch of cam (97) is actually third speed notch.

6. Adjust the link end of hydraulic shift spool (15) until the opposite end is even with face (W) of automatic selector valve (7).

7. Put shift spool (50) against cover (99).

8. Adjust the link of shift spool (50) to get distance (X) of 1.97 in. (50.0 mm), from the valve body to the center of the link notch.

SHIFT CYLINDER GROUP
50. Shift spool. 99. Cover. X. Distance of 1.97 in. (50.0 mm), from the valve body to the center of the link notch.

Adjustment Of Shift Points On Machines With PC Engines

7D978 Swivel Tee5P5005 Reducer6V3081 Hose Assembly8M2885 Pressure Gauge [200 psi (1380 kPa)]

The screws for shift adjustment are inside the transmission case behind plugs (100), (102), (103) and (104). Screw (A) behind plug (100) changes all downshift points and supply oil to the governor. One clockwise turn of screw (A) makes downshift points go DOWN approximately 20 engine rpm.

LOCATION OF ADJUSTMENT SCREWS
100. Plug for access hole to screw (A) (for adjustment of reference pressure for all downshifts). 101. Plug for access hole to screw (E) (for adjustment of pressure of priority valve). 102. Plug for access hole to screw (F) (for adjustment of reference pressure for first to second speed upshift). 103. Plug for access hole to screw (H) (for adjustment of reference pressure for second to third, fourth to fifth and sixth to seventh speed upshifts). 104. Plug for access hole to screw (J) (for adjustment of reference pressure for third to fourth and fifth to sixth speed upshifts).

Screw (F) behind plug (102) changes the first to second speed upshift point. Screw (J) behind plug (104) changes the third to fourth and fifth to sixth speed upshift points. Screw (H) behind plug (103) changes the second to third, fourth to fifth and sixth to seventh speed upshift points. One clockwise turn of screws (F), (H) and (J) makes the upshift points of that specific speed change, (see SHIFT POINT CHART) go UP approximately 15 engine rpm.

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Before an adjustment is made to the shift points, make sure the rear drive shaft is disconnected from the transmission.

1. Disconnect hose (105) from sequence and pressure control valve (46). Install the swivel tee between the end of hose (105) and sequence and pressure control valve (46).

2. Connect the hose assembly and the 0 to 200 psi (0 to 1380 kPa) pressure gauge on the swivel tee and also at pressure tap (DD) for the governor.

3. Start the engine and let the transmission oil get to normal temperature of operation while in NEUTRAL position.

4. Install a tachometer.

PRESSURE TAP FOR THE LOCK-UP CLUTCH
46. Sequence and pressure control valve. 105. Hose from sequence and pressure control valve to torque converter.

5. Check engine high idle with the governor control pedal. Adjust the linkage and/or governor to get correct high idle.

6. Use the procedure given on Page 7 to check the pressure setting of the priority valve.

7. Check the pressure of the oil to the governor at pressure tap (DD). Pressure must be approximately 100 psi (690 kPa). If the pressure is not correct, turn screw (A) to get the correct pressure.

NOTE: Oil supply pressure for the governor is changed when adjustment is made to downshift points.

8. Use the air pressure regulator to control engine speed at the transmission.

9. Use the procedure that follows to put the shift points out of adjustment.

a. Turn screw (F) out (counterclockwise) three turns.

b. Turn screw (H) in (clockwise) four turns.

c. Turn screw (J) in (clockwise) three turns.

10. With the engine running, transmission in NEUTRAL, shift the transmission selector lever or the shaft on top of the transmission to 3rd speed position.

11. Increase engine speed to 2130 ± 30 rpm for the 2nd to 3rd speed upshift. The transmission must shift from 1st to 2nd as the engine speed is increased. With engine speed constant at 2130 rpm, turn screw (H) out (counterclockwise) until the transmission makes a shift to 3rd speed.

12. Make sure engine speed is constant at 2130 ± 30 rpm for the 3rd to 4th speed upshift. Move the transmission selector lever or the shaft on top of the transmission to 4th speed position. Turn screw (J) out (counterclockwise) until the transmission makes a shift to 4th speed.

13. Decrease engine speed slowly to 1502 ± 30 rpm for the 4th to 3rd speed downshift. If the engine speed is not correct for the 4th to 3rd speed downshift, turn screw (A) to get the downshift within tolerance.

PRESSURE TAPS FOR SHIFT GOVERNOR
AA. Shift pressure tap "A" (first through third). BB. Shift pressure tap "B" (third through fifth). CC. Shift pressure tap "C" (fifth through seventh). DD. Supply pressure tap for governor.

NOTE: One turn of screw (A) will change the downshift rpm approximately 20 rpm. The rpm will decrease when screw (A) is turned clockwise and will increase when screw (A) is turned counterclockwise. Any movement of screw (A) will also change the upshift speeds.

NOTE: The transmission may downshift from 3rd to 2nd at the same time it downshifts from 4th to 3rd. This is because both downshift speeds are the same.

14. Decrease engine speed slowly to 1417 ± 30 rpm for a 2nd to 1st speed downshift. Turn screw (F) in (clockwise) until the transmission makes a shift from 2nd to 1st speed.

15. Check and make a record of all upshift and downshift speeds. Decrease the engine speed 200 rpm before the transmission selector lever or the shaft on top of the transmission is moved to the next higher speed.

16. Make a comparison of all speeds with the speeds given in the SHIFT POINT CHART. Make adjustments to the screws to get all shift points as near as possible to the mean (average) speed that is given in the chart.

EXAMPLE:

If the shift points, controlled by the same adjustment screw [screw (H) for 2nd to 3rd, 4th to 5th and 6th to 7th, screw (J) for 3rd to 4th and 5th to 6th], are not all at the correct engine speed, they must be adjusted so the mean of the shift points is at the mean engine speed given in the SHIFT POINT CHART. See the example chart that follows:

17. To check the lock-up clutch shift point:

a. Move the transmission selector lever to FIRST speed position. The transmission must shift to first speed. Increase engine speed to 1700 rpm. The pressure of the gauge at the tee fitting for the lock-up clutch must have indication of lock-up clutch engagement [approximately 160 psi (1100 kPa)]. The indication will be a shift from converter drive to engagement of the lock-up clutch (direct drive) when engine speed is 1509 ± 15 rpm. An adjustment can be made to adjustment screw (N) on the sequence and pressure control valve to get the engagement at the correct engine speed.

b. Make the engine speed go down to 1390 ± 30 rpm. The pressure indication on the gauge must have indication of lock-up clutch disengagement (not engaged) [0 psi (0 kPa)].

c. Increase the engine speed to 1700 rpm. Slowly make the engine speed go down. Lock-up clutch must disengage.

d. Turn adjustment screw (N), if needed, to let the lock-up clutch operate at the correct engine speed.

18. If an adjustment can not be made to the shift points or a shift point, make a check of the operation of the governor as follows:

a. Use a 0 to 200 psi (0 to 1380 kPa) pressure gauge to check pressure taps (AA), (BB) and (CC).

NOTE: Use the same gauge to check all three pressures so that there will be no error in the readings.

b. Refer to SHIFT GOVERNOR PERFORMANCE CHART for approximate pressure of the governor at each shift point.

c. If the pressures of the governor are not correct, clean or install a new governor and check the pressures again.

d. Remove pressure gauges at pressure taps (AA), (BB) and (CC) and do Steps 1 through 16 again.

19. Shut off the engine. Remove the pressure gauges and the tee fittings. Connect hose (105) to sequence and pressure control valve (46).

Adjustment Of Shift Points On Machines With DI Engines

7D978 Swivel Tee5P5005 Reducer6V3081 Hose Assembly8M2885 Pressure Gauge [200 psi (1380 kPa)]

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Before an adjustment is made to the shift points, make sure the rear drive shaft is disconnected from the transmission.

1. Disconnect hose (105) from sequence and pressure control valve (46). Install the swivel tee between the end of hose (105) and sequence and pressure control valve (46).

2. Connect the hose assembly and the 0 to 200 psi (0 to 1380 kPa) pressure gauge on the swivel tee and also at pressure tap (DD) for the governor.

3. Start the engine and let the transmission oil get to normal temperature of operation while in NEUTRAL position.

4. Install a tachometer.

PRESSURE TAP FOR THE LOCK-UP CLUTCH
46. Sequence and pressure control valve. 105. Hose from sequence and pressure control valve to torque converter.

5. Check engine high idle with the governor control pedal. Adjust the linkage and/or governor to get correct high idle.

6. Use the procedure given on Page 7 to check the pressure setting of the priority valve.

7. Check the pressure of the oil to the governor at pressure tap (DD). Pressure must be approximately 100 psi (690 kPa). If the pressure is not correct, turn screw (A) to get the correct pressure.

NOTE: Oil supply pressure for the governor is changed when adjustment is made to downshift points.

8. Use the air pressure regulator to control engine speed at the transmission.

9. Use the procedure that follows to put the shift points out of adjustment.

a. Turn screw (F) out (counterclockwise) three turns.

b. Turn screw (H) in (clockwise) four turns.

c. Turn screw (J) in (clockwise) three turns.

10. With the engine running, transmission in NEUTRAL, shift the transmission selector lever or the shaft on top of the transmission to 3rd speed position.

11. Increase engine speed to 2100 ± 30 rpm for the 2nd to 3rd speed upshift. The transmission must shift from 1st to 2nd as the engine speed is increased. With engine speed constant at 2100 rpm, turn screw (H) out (counterclockwise) until the transmission makes a shift to 3rd speed.

12. Make sure engine speed is constant at 2100 ± 30 rpm for the 3rd to 4th speed upshift. Move the transmission selector lever or the shaft on top of the transmission to 4th speed position. Turn screw (J) out (counterclockwise) until the transmission makes a shift to 4th speed.

13. Decrease engine speed slowly to 1480 ± 30 rpm for 4th to 3rd speed downshift. If the engine speed is not correct for the 4th to 3rd speed downshift, turn screw (A) to get the downshift within tolerance.

NOTE: The transmission may downshift from 3rd to 2nd at the same time it downshifts from 4th to 3rd. This is because both downshift speeds are the same.

14. Decrease engine speed slowly to 1399 ± 30 rpm for a 2nd to 1st speed downshift. Turn screw (F) in (clockwise) until the transmission makes a shift from 2nd to 1st speed.

15. Check and make a record of all upshift and downshift speeds. Decrease the engine speed 200 rpm before the transmission selector lever of the shaft on top of the transmission is moved to the next higher speed.

EXAMPLE:

17. To check the lock-up clutch shift point:

a. Move the transmission selector lever to FIRST speed position. The transmission must shift to first speed. Increase engine speed to 1700 rpm. The pressure of the gauge at the tee fitting for the lock-up clutch must have indication of lock-up clutch engagement [approximately 160 psi (1100 kPa)]. The indication will be a shift from converter drive to engagement of the lock-up clutch (direct drive) when engine speed is 1450 ± 15 rpm. An adjustment can be made to adjustment screw (N) on the sequence and pressure control valve to get the engagement at the correct engine speed.

b. Make the engine speed go down to 1340 ± 30 rpm. The pressure indication on the gauge must have indication of lock-up clutch disengagement (not engaged) [0 psi (0 kPa)].

c. Increase the engine speed to 1700 rpm. Slowly make the engine speed go down. Lock-up clutch must disengage.

d. Turn adjustment screw (N), if needed, to let the lock-up clutch operate at the correct engine speed.

18. If an adjustment can not be made to the shift points or a shift point, make a check of the operation of the governor as follows:

a. Use a 0 to 200 psi (0 to 1380 kPa) pressure gauge to check pressure taps (AA), (BB) and (CC).

NOTE: Use the same gauge to check all three pressures so that there will be no error in the readings.

b. Refer to SHIFT GOVERNOR PERFORMANCE CHART for approximate pressures of the governor at each shift point.

c. If the pressures of the governor are not correct, clean or install a new governor and check the pressures again.

d. Remove pressure gauges at pressure taps (AA), (BB) and (CC) and do Steps 1 through 16 again.

19. Shut off the engine. Remove the pressure gauges and the tee fitting. Connect hose (105) to sequence and pressure control valve (46).

Test Of The Operation Of The Torque Converter

7S8887 Quick-Connect Plug (1/4"-18 NPT Male).

7S8890 Nipple.7S8894 Hose Assembly.7S8895 Socket Assembly.

NOTE: The rear drive shaft must be installed for this test. This test is also used to check the pressure setting of outlet relief valve (68) for the torque converter.

1. Remove the plug at pressure tap (T).

2. Install plug (93) at pressure tap (T).

3. Install hose group (76), as shown, to socket (79) and plug (93).

4. Install a lever or Vise-Grip pliers on transmission selector shaft (87).

5. Let the engine run at low idle rpm. Manually shift the transmission to third speed (fifth detent position from reverse).

NOTE: There is a detented position between first and second speeds that is not used.

6. Activate the brakes.

7. Run the engine at high idle rpm.

8. The speed of the engine must be between 1939 and 2069 rpm for PC engines (1913 to 2043 rpm for DI engines). The machine will stay in torque converter drive as long as the transmission output is zero.

CONNECTION AT PRESSURE TAP (T)
76. Hose group for operation of the hold valve. 93. Plug (male).

Pressure Test for Outlet Relief Valve (68) for the Torque Converter

9. Stop the engine and install a 0 to 100 psi (0 to 690 kPa) pressure gauge at pressure tap (R).

10. Do Steps 1 through 8 again and look at the pressure gauge.

11. The pressure at pressure tap (R) must be 60 ± 10 psi (415±70 kPa).

NOTE: To change pressure, add or remove spacers (92) for outlet relief valve (68).

LOCATION OF SPACERS FOR OUTLET RELIEF VALVE FOR TORQUE CONVERTER
92. Spacers.

Transmission Electrical Controls

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Make sure the machine disconnect switch is OFF before any connections are made.

NOTE: In all electrical tests where red (positive) battery lead wire (1) is used, connect the lead wire to the positive (+) terminal of the batteries as shown.

CONNECTION OF THE RED (POSITIVE) BATTERY LEAD WIRE
1. Red (positive) battery lead wire.

NOTE: In all electrical tests, except the TEST OF MACHINE BATTERY VOLTAGE, where black (negative) battery lead wire (2) is used, connect the lead wire to a good ground on the machine frame as shown.

CONNECTION OF THE BLACK (NEGATIVE) BATTERY LEAD WIRE
2. Black (negative) battery lead wire.

NOTE: The tester lamps are for use with a 24 volt system and, if outside light is bright, or if the electrical system has 10 volts or less, it is probable that the test lamp will not be bright enough to be seen.

NOTE: Always make a check of the 1P3550 Wiring Tester Group before any tests are made with it. Make reference to Special Instruction Form No. GMG00516. The 5P6590 Wiring Tester Group does not need to have a check made before every test.

PINS INSTALLED IN BODY OF TRUCK

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In all transmission electrical tests, do the steps that follow:

1. Lift the body and install the two pins at the rear of the truck.
2. Disconnect the hoist control linkage at the hydraulic tank.
3. Let only approved personnel on the machine. Keep other personnel off the machine.

HOIST CONTROL LINKAGE DISCONNECTED AT THE HYDRAULIC TANK

1P3550 or 5P6590 Wiring Tester Group.1P2857 Battery Lead Wire (red).1P2858 Battery Lead Wire (black).5P959 Ground Adapter (16 pin).5P6597 Harness (2 pin).5P6598 Harness (16 pin).8S4627 Continuity Tester.5P7277 Voltage Tester.

Index Of Tests

1. TEST OF MACHINE BATTERY VOLTAGE

2. SYSTEM TEST AT TEST POINT A

3. TEST FOR VOLTAGE TO THE TRANSMISSION ELECTRICAL CONTROLS

4. SYSTEM TEST AT TEST POINT B

5. TEST OF THE CAB AND CHASSIS HARNESSES FOR SHORTS

6. TEST OF THE CAB AND CHASSIS HARNESSES FOR GROUNDS

7. TEST OF THE CAB AND CHASSIS HARNESSES FOR CONTINUITY

8. TEST OF THE CAB HARNESS FOR SHORTS

9. TEST OF THE CAB HARNESS FOR GROUNDS

10. TEST OF THE CAB HARNESS FOR CONTINUITY

11. TEST OF THE CHASSIS HARNESS FOR SHORTS

12. TEST OF THE CHASSIS HARNESS FOR GROUNDS

13. TEST OF THE CHASSIS HARNESS FOR CONTINUITY

14. TEST OF THE MANUAL SWITCH AND SWITCH HARNESS

15. TEST OF THE SLAVE SWITCH AND SWITCH HARNESS

16. TEST OF A SWITCH HARNESS FOR SHORTS

17. TEST OF A SWITCH HARNESS FOR GROUNDS

18. TEST OF A SWITCH HARNESS FOR CONTINUITY

19. TEST OF A SOLENOID

Location Of Electrical Test Points

TEST POINT A (At slave switch)
3. Chassis harness. 4. Slave switch.

TEST POINT B (At shift console)
5. Cab harness. 6. Shift console.

TEST POINTS C & D (At shift solenoids)
3. Chassis harness. 7. Downshift solenoid. 8. Upshift solenoid.

TEST POINT E (Cab Connection)
3. Chassis harness. 5. Cab harness.

WIRING DIAGRAM OF MANUAL (CONSOLE) SWITCH AND CAB HARNESS (NEUTRAL POSITION)

WIRING DIAGRAM OF SLAVE (TRANSMISSION) SWITCH AND CHASSIS HARNESS (NEUTRAL POSITION)

1. Test Of Machine Battery Voltage

TEST OF MACHINE BATTERY VOLTAGE
1. Red (positive) battery lead wire. 2. Black (negative) battery lead wire.

NOTE: Always test the battery first when troubleshooting an electrical system. A test of the battery will give a good indication of the amount of charge in the batteries.

1. Connect the 1P3550 or the 5P6590 Wiring Tester Group as shown.

NOTE: Connect lead wires to the batteries first, then to the tester.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch OFF and the POWER switch to EXTERNAL.

2. Read the battery voltage on the meter. See the chart that follows to make an analysis of the battery voltage.

3. If the voltage is low, put a charge to the batteries before more tests of the electrical system are made.

4. If the battery charge is very low, a more thorough check must be made. Use either the 5P957 or 5P3514 Coolant and Battery Fluid Tester to check the specific gravity of the electrolyte in each battery cell. Use the results of both the voltage test and the specific gravity test to get battery condition. Use the chart that follows to get battery condition.

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When the batteries are tested, connect the battery lead wires to the batteries first, then make the last connections at the tester.

2. System Test At Test Point A

1. Turn the machine disconnect switch to OFF.

2. To disconnect the transmission neutralizer from the system, use the procedure that follows:

a. Remove the rear cover on the cab.

TRANSMISSION NEUTRALIZER (CONNECTED)
10. Dark green wire. 11. Light blue wires (two) from the transmission neutralizer. 12. Lower light blue wires (two).

b. Disconnect one dark green wire (10) and two light blue wires (11) at their connections.

c. Connect two lower light blue wires (12) as shown.

3. Connect harness (9) for 16 pins to the tester and also at Test Point A as shown.

TRANSMISSION NEUTRALIZER (DISCONNECTED)
12. Lower light blue wires (two).

CONNECTION AT TEST POINT A
3. Chassis harness. 4. Slave switch. 9. Harness for 16 pins.

4. Connect the black (negative) battery lead wires to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

5. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON and the POWER switch to INTERNAL.

6. Turn the machine disconnect switch to ON and start the engine.

7. With the engine at low idle, put the parking brake and front brake controls ON and activate the service brakes.

TESTER WITH TRANSMISSION IN NEUTRAL

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Do not release the brakes at any time during this test.

8. Move the transmission selector lever on the shift console to all speed positions. In a good system test, the LAMPS of the tester that come ON must be the same as shown in the chart. The upshift or downshift lamps come ON only for a moment when the transmission makes a shift.

System Test For Voltage

NOTE: Use this test during a system test to check the voltage at Test Point A.

CHECK OF VOLTAGE WITH TRANSMISSION IN NEUTRAL

1. Turn the SELECTOR switch to the same position as the lamp that is ON. For example, in NEUTRAL (A lamp ON) turn the SELECTOR switch to A.

2. The METER on the tester will give an indication of the voltage in each wire at Test Point A.

NOTE: Resistance, caused by wire size and/or length, connectors and/or corrosion, in an electrical circuit will decrease voltage. The meaning of this is, the more distance between the batteries and the test, the smaller the voltage indication will be on the METER.

3. Test For Voltage To The Transmission Electrical Controls

1. Turn the machine disconnect switch to OFF.

2. Disconnect cab harness (5) at Test Point B.

3. Turn the machine disconnect switch to ON.

4. Connect the end of voltage tester (13), that has a clip, to a good ground on the machine frame near Test Point B.

5. At Test Point B, put the other end (point) of the voltage tester in contact with socket 0. The lamp in the tester will come ON if there is voltage to the transmission electrical controls. The lamp of the tester will also come ON at socket L.

TEST FOR VOLTAGE AT TEST POINT B
5. Cab harness. 13. Voltage tester.

4. System Test At Test Point B

1. Turn the machine disconnect switch to OFF.

2. To disconnect the transmission neutralizer from the system, use the procedure that follows:

a. Remove the rear cover on the cab.

TRANSMISSION NEUTRALIZER (CONNECTED)
10. Dark green wire. 11. Light blue wires (two) from the transmission neutralizer. 12. Lower light blue wires (two).

b. Disconnect one dark green wire (10) and two light blue wires (11) at their connections.

c. Connect two lower light blue wires (12) as shown.

TRANSMISSION NEUTRALIZER (DISCONNECTED)
12. Lower light blue wires (two).

3. Connect harness (9) for 16 pins to the tester and also at Test Point B as shown.

CONNECTION AT TEST POINT B
5. Cab harness. 6. Shift console. 9. Harness for 16 pins.

4. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

5. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON and the POWER switch to INTERNAL.

6. Turn the machine disconnect switch to ON and start the engine.

7. With the engine at low idle, put the parking brake and front brake controls ON and activate the service brakes.

TESTER WITH TRANSMISSION IN FOURTH

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Do not release the brakes at any time during this test.

8. Move the transmission selector lever on the shift console to all speed positions. In a good system test, the LAMPS of the tester that come ON must be the same as shown in the chart. Lamps L and O are ON in all speeds.

System Test For Voltage

NOTE: Use this test during a system test to check the voltage at Test Point B.

1. Turn the SELECTOR switch to the same position as the lamp that is ON. For example, in NEUTRAL, (A lamp ON) turn the SELECTOR switch to A.

2. The METER on the tester will give an indication of the voltage in each wire at Test Point B.

CHECK OF VOLTAGE WITH TRANSMISSION IN FOURTH

NOTE: Resistance caused by wire size and/or length, connectors and/or corrosion, in an electrical circuit will decrease voltage. The meaning of this is, the more distance between the batteries and the test, the smaller the voltage indication will be on the METER.

5. Test Of The Cab And Chassis Harnesses For Shorts

1. Turn the machine disconnect switch to OFF.

2. Disconnect BOTH ends of the harnesses at Test Points A and B.

CONNECTION AT TEST POINT B
5. Cab harness. 9. Harness for 16 pins.

3. Connect harness (9) for 16 pins to the tester and also to cab harness (5) at Test Point B.

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NOTICE

Never connect the other end of the machine harness during this test.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

TEST FOR SHORTS WITH SELECTOR SWITCH AT C (NEUTRAL WIRE)

NOTE: There are no wires connected to M, N and P.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

6. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON, the POWER switch to EXTERNAL and the JUMPER wire across the battery power bulb.

7. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

8. Turn the SELECTOR switch through all positions. The LAMPS that come ON must be the same as shown in the chart, if there are no shorts in the harnesses.

6. Test Of The Cab And Chassis Harnesses For Grounds

1. Turn the machine disconnect switch to OFF.

2. Disconnect BOTH ends of the harnesses at Test Points A and B.

3. Connect harness (9) for 16 pins to the tester and also to cab harness (5) at Test Point B.

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NOTICE

Never connect the other end of the machine harness during this test.

CONNECTION AT TEST POINT B
5. Cab harness. 9. Harness for 16 pins.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

6. Put the CONTINUITY TEST switch ON and the LAMPS CONTROL switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch OFF and the POWER switch to EXTERNAL.

TEST FOR GROUNDS WITH SELECTOR SWITCH AT E (FIRST SPEED WIRE)

7. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

8. Turn the SELECTOR switch through all positions. The CONTINUITY LAMP will come ON if one of the wires in the harness is grounded.

NOTE: With the SELECTOR switch at position K, the CONTINUITY LAMP will come ON. This is because of the back-up alarm relay and the back-up light. Turn the CONTINUITY TEST switch to OFF and the back-up alarm will come ON.

NOTE: If the machine has a transmission neutralizer, the CONTINUITY LAMP will come ON and the relay will make a sound (click) when the SELECTOR switch is at position B. If the diodes in the transmission neutralizer are bad, the CONTINUITY LAMP will come ON when SELECTOR switch is at position C.

7. Test Of The Cab And Chassis Harnesses For Continuity

1. Turn the machine disconnect switch to OFF.

2. Disconnect BOTH ends of the harnesses at Test Points A and B.

3. Connect harness (9) for 16 pins to the tester and also to cab harness (5) at Test Point B.

4. Connect ground adapter (14) for 16 pins to chassis harness (3) at Test Point A. Connect the other end to a good ground on the machine frame.

CONNECTION AT TEST POINT B
5. Cab harness. 9. Harness for 16 pins.

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NOTICE

Do not connect the ground adapter at Test Point B.

CONNECTION AT TEST POINT A
3. Chassis harness. 14. Ground adapter for 16 pins.

5. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

6. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

7. Put the CONTINUITY TEST switch ON and the LAMPS CONTROL switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch OFF and the POWER switch to EXTERNAL.

8. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

TEST FOR CONTINUITY WITH SELECTOR SWITCH AT A (SEVENTH SPEED WIRE)

9. Turn the SELECTOR switch through all positions. The CONTINUITY LAMP will come ON the same as shown in the chart, if there is continuity in the harnesses.

NOTE: The transmission neutralizer has no effect on this test.

NOTE: There are no wires connected to M, N and P.

8. Test Of The Cab Harness For Shorts

1. Turn the machine disconnect switch to OFF.

2. Disconnect BOTH ends of the harness at Test Points B and E.

3. Connect harness (9) for 16 pins to the tester and also to cab harness (5) at Test Point B.

CONNECTION AT TEST POINT B
5. Cab harness. 9. Harness for 16 pins.

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NOTICE

Never connect the other end of the machine harness during this test.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

6. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON, the POWER switch to EXTERNAL and the JUMPER wire across the battery power bulb.

TEST FOR SHORTS WITH SELECTOR SWITCH AT C (NEUTRAL WIRE)

NOTE: There are no wires connected to M, N and P.

7. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

8. Turn the SELECTOR switch through all positions. The LAMPS that come ON must be the same as shown in the chart, if there are no shorts in the harness.

9. Test Of The Cab Harness For Grounds

1. Turn the machine disconnect switch to OFF.

2. Disconnect BOTH ends of the harness at Test Points B and E.

3. Connect harness (9) for 16 pins to the tester and also to cab harness (5) at Test Point B.

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NOTICE

Never connect the other end of the machine harness during this test.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

CONNECTION AT TEST POINT B
5. Cab harness. 9. Harness for 16 pins.

6. Put the CONTINUITY TEST switch ON and the LAMPS CONTROL switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch OFF and the POWER switch to EXTERNAL.

7. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

8. Turn the SELECTOR switch through all positions. The CONTINUITY LAMP will come ON if one of the wires in the harness is grounded.

TEST FOR GROUNDS WITH SELECTOR SWITCH AT E (FIRST SPEED WIRE)

10. Test Of The Cab Harness For Continuity

1. Turn the machine disconnect switch to OFF.

2. Disconnect BOTH ends of cab harness (5) at Test Points B and E.

GROUND ADAPTER CONNECTED AT TEST POINT B
5. Cab harness. 14. Ground adapter for 16 pins.

3. Connect ground adapter (14) for 16 pins to the harness at Test Point B. Connect the other end to a good ground on the machine frame.

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NOTICE

Do not turn machine disconnect switch ON.

4. Connect the end of continuity tester (15), that has a clip, to a good ground on the machine frame near Test Point E.

TEST FOR CONTINUITY AT TEST POINT E (FIRST SPEED WIRE)
5. Cab harness. 15. Continuity tester.

5. At Test Point E put the other end (point) of the continuity tester in contact with sockets A, B, C, D, E, I, J, O, P and V. Each time the point comes in contact with a pin, the lamp in the tester will come ON. If the lamp does not come ON, there is an open (break) in the wire.

11. Test Of The Chassis Harness For Shorts

1. Turn the machine disconnect switch to OFF.

2. Disconnect the ends of the harness at Test Points A, C, D and E.

3. Connect harness (9) for 16 pins to the tester and also to chassis harness (3) at Test Point A.

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NOTICE

Never connect the other ends of the machine harness during this test.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

CONNECTION AT TEST POINT A
3. Chassis harness. 9. Harness for 16 pins.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

6. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON, the POWER switch to EXTERNAL and the JUMPER wire across the battery power bulb.

7. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

8. Turn the SELECTOR switch through all positions. The LAMPS that come ON must be the same as shown in the chart, if there are no shorts in the harness.

TEST FOR SHORTS WITH SELECTOR SWITCH AT C (NEUTRAL WIRE)

NOTE: There are no wires on connections M, N, O and P.

12. Test Of The Chassis Harness For Grounds

1. Turn the machine disconnect switch to OFF.

2. Disconnect the ends of the harness at Test Points A, C, D, and E.

3. Connect harness (9) for 16 pins to the tester and also to chassis harness (3) at Test Point A.

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NOTICE

Never connect the other ends of the machine harness during this test.

CONNECTION AT TEST POINT A
3. Chassis harness. 9. Harness for 16 pins.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

6. Put the CONTINUITY TEST switch ON and the LAMPS CONTROL switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch OFF and the POWER switch to EXTERNAL.

7. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

8. Turn the SELECTOR switch through all positions. The CONTINUITY LAMP will come ON if one of the wires in the harness is grounded.

TEST FOR GROUNDS WITH SELECTOR SWITCH AT E (FIRST SPEED WIRE)

13. Test Of The Chassis Harness For Continuity

1. Turn the machine disconnect switch to OFF.

GROUND ADAPTER CONNECTED AT TEST POINT A
3. Chassis harness. 14. Ground adapter for 16 pins.

2. Disconnect the ends of chassis harness (3) at Test Points A, C, D and E.

3. Connect ground adapter (14) for 16 pins to the harness at Test Point A. Connect the other end to a good ground on the machine frame.

4. Connect the end of continuity tester (15), that has a clip, to a good ground on the machine frame near Test Point E.

5. At Test Point E, put the other end (point) of the continuity tester in contact with pins A, B, C, D, E, I, J, O, P and V. Each time the point comes in contact with a pin, the lamp will come ON. If the lamp does not come ON, there is an open (break) in the wire.

TEST FOR CONTINUITY AT TEST POINT E
3. Chassis harness. 15. Continuity tester.

6. Connect the end of continuity tester (15) that has a clip, to a good ground on the machine frame near Test Points C and D.

TEST FOR CONTINUITY AT TEST POINTS C AND D
3. Chassis harness. 14. Ground adapter. 15. Continuity tester.

7. Put the other end (point) of the continuity tester in contact with pin A at Test Points C and D. If the lamp does not come ON, there is an open (break) in the wire.

8. Disconnect ground adapter (14) for 16 pins from chassis harness (3).

9. Make sure the continuity tester is connected to a good ground. Put the point of continuity tester (15) in contact with pin B at Test Points C and D. If the lamp does not come ON, there is an open (break) in the ground wire of the chassis harness.

14. Test Of The Manual Switch And Switch Harness

1. Turn the machine disconnect switch to OFF.

2. Disconnect the cab harness at Test Point B.

3. Connect harness (9) for 16 pins to the tester and also to shift console (6) at Test Point B.

CONNECTION TO THE SHIFT CONSOLE AT TEST POINT B
6. Shift console. 9. Harness for 16 pins.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

6. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON and the POWER switch to INTERNAL.

7. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

8. Turn the SELECTOR switch to position O.

9. Move the transmission selector lever through all speed positions. The LAMPS of the tester that come ON must be the same as shown in the chart, if the switch and harness are good.

TEST OF THE MANUAL SWITCH (SECOND SPEED)

15. Test Of The Slave Switch And Switch Harness

1. Turn the machine disconnect switch to OFF.

2. Disconnect the chassis harness at Test Point A.

3. Connect harness (9) for 16 pins to the tester and also to the slave switch at Test Point A.

4. Remove cover (16) from slave switch (4).

5. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

6. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

7. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

TEST POINT A
4. Slave switch. 9. Harness for 16 pins. 16. Cover.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON, the POWER switch to EXTERNAL and the JUMPER wire across the battery power bulb.

8. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

MOVEMENT OF THE SLAVE SWITCH WITH A WRENCH
17. 1/4 in. open end wrench.

9. Use a 1/4 in. open end wrench (17) to turn the slave switch to all speed positions. At each speed position also turn the SELECTOR switch to all positions. The LAMPS of the tester that come ON must be the same as shown in the chart, if the switch and harness are good.

10. Turn the machine disconnect switch to OFF. Install cover (16) and the harness at Test Point A.

NOTE: There is a space (detent) between NEUTRAL and FIRST that is not used. This is terminal 1. For more information on this, see the section TRANSMISSION ELECTRICAL SYSTEM in the 768C TRACTOR & 769C TRUCK POWER TRAIN, SYSTEMS OPERATION, TESTING & ADJUSTING, Form No. SENR7808.

TEST OF THE SLAVE SWITCH IN THIRD SPEED WITH SELECTOR SWITCH AT B

16. Test Of A Switch Harness For Shorts

1. Remove the switch harness (manual or slave) that is to be tested.

2. Connect harness (9) for 16 pins to the tester and also to switch harness (18).

CONNECTION TO THE SWITCH HARNESS
9. Harness for 16 pins. 18. Switch harness.

3. Connect the red (positive) battery lead wire to the positive (+) terminal of the batteries. Connect the other end to the positive (+) terminal of the tester.

4. Connect the black (negative) battery lead wire to the negative (-) terminal of the batteries. Connect the other end to the negative (-) terminal of the tester.

NOTE: During this test, make sure that the ends of the wires of the switch harness do not come in contact with each other.

5. Put the LAMPS CONTROL switch ON and the CONTINUITY TEST switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch ON, the POWER switch to EXTERNAL and the JUMPER wire across the battery power bulb.

TEST FOR SHORTS WITH SELECTOR SWITCH AT C (NEUTRAL WIRE)

6. Turn the SELECTOR switch through all positions. If the switch harness has no short, only one lamp will come ON at each position of the SELECTOR switch.

17. Test Of A Switch Harness For Grounds

1. Remove the switch harness (manual or slave) that is to be tested.

2. Connect harness (9) for 16 pins to the tester and also to switch harness (18).

CONNECTION TO THE SWITCH HARNESS
9. Harness for 16 pins. 18. Switch harness.

3. Connect the red (positive) battery lead wire to the positive (+) terminal of the batteries. Connect the other end to the positive (+) terminal of the tester.

4. Connect the black (negative) battery lead wire to the negative (-) terminal of the batteries. Connect the other end to the negative (-) terminal of the tester.

TEST FOR GROUNDS WITH SELECTOR SWITCH AT E (FIRST SPEED WIRE)

NOTE: During this test, make sure that the ends of the wires of the switch harness do not come in contact with each other.

5. Put the CONTINUITY TEST switch ON and the LAMPS CONTROL switch OFF.

NOTE: On the 1P3550 Wiring Tester, put the GROUND switch OFF and the POWER switch to EXTERNAL.

6. Turn the SELECTOR switch through all positions. The CONTINUITY LAMP will come ON if one of the wires in the harness is grounded.

18. Test Of A Switch Harness For Continuity

1. Remove the switch harness (manual or slave) that is to be tested.

2. Connect the clip of continuity tester (15) to the end of the wire of the switch harness that is to be tested.

3. Put the other end (point) of continuity tester (15) in contact with the correct pin of switch harness (18). If there is continuity in the wire, the lamp in the tester will come ON when the point comes in contact with the pin.

TEST OF A SWITCH HARNESS FOR CONTINUITY
15. Continuity tester. 18. Switch harness.

19. Test Of A Solenoid

1. Turn the machine disconnect switch to OFF.

2. Disconnect the chassis harness at Test Point C to test upshift solenoid (8). Disconnect the chassis harness at Test Point D to test downshift solenoid (7).

3. Connect harness (19) for two pins to the tester and also to the solenoid at Test Point C or D.

CONNECTION TO THE DOWNSHIFT SOLENOID AT TEST POINT D
3. Chassis harness. 7. Downshift solenoid. 8. Upshift solenoid. 19. Harness for two pins.

4. Connect the red (positive) battery lead wire to the positive (+) terminal of the tester. Connect the other end to the positive (+) terminal of the batteries.

5. Connect the black (negative) battery lead wire to the negative (-) terminal of the tester. Connect the other end to a good ground on the machine frame.

6. Turn the machine disconnect switch to ON. The METER will show approximately 24 volts.

7. Push the SOLENOID TEST CONTROL down. If the solenoid is good, a click (noise made when the solenoid is activated) will be heard.

8. Release the SOLENOID TEST CONTROL. If the solenoid is good, a click will again be heard.

NOTE: If the noise around the machine is too loud and the click can not be heard, put your hand on the solenoid housing. The movement of the solenoid plunger, when the tester button is pushed and released, can be felt.

TEST OF THE DOWNSHIFT SOLENOID