Bench Test Procedure for a 990K Wheel Loader and 844K Compactor Transmission {3030, 3073} Caterpillar

Wheel Dozer

844K (S/N: MBE1-UP; M4R1-UP; KLS1-UP; K4Y1-UP)

Wheel Loader

990K (S/N: DJK1-UP; A9P1-UP; M9P1-UP; K9X1-UP)

Introduction

© 2019 Caterpillar All Rights Reserved. This document is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law. Information contained in this document is considered Caterpillar: Confidential Yellow.

This document contains the necessary information that is required to bench test a specific transmission arrangement. Refer to Table 2 for the correct arrangements. Bench testing the transmission ensures correct assembly and operation of the component. Rotating a transmission provides the most conclusive evaluation. Testing allows the dealer to ensure that the transmission will operate properly in the machine. The specifications in this document are specific to bench testing the component. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This document must be used with the latest technical information that is available from Caterpillar.

For questions or additional information concerning this guideline, submit a form for feedback in the Service Information System. To address an urgent issue, use the following resources to communicate your request to Caterpillar Repair Process Engineering:

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Follow all safety warnings. Most accidents that involve product operation, maintenance, or repair are caused by failure to observe safety warnings. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. Personnel must be properly trained to perform maintenance, repair, or operate any machine. Safety precautions and warnings are provided in this instruction and on Caterpillar products. These warnings should be observed before performing any procedures. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on Caterpillar products are not all inclusive.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING", or “CAUTION”. The “WARNING” Safety Alert Symbol is shown in illustration below.

Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your Safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, specifications, and illustrations that exist in this document are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Collecting the Test Data

Since conditions vary for each test bench, use the data that is collected from your test bench. The collected data is used to compare test results. The data should be collected and maintained by the operator.

Data from each transmission arrangement is collected and stored. Averages from each transmission arrangement are often used to compare values on portions of transmission tests. Always compare data that is collected from the same transmission arrangement that is being tested. Averages for the last 20 transmission arrangements should be maintained.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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Personal injury or death can result from not following the proper procedures. To avoid the possibility of injury or death, follow the established procedure.

Tools Needed

Note: Pressures will be sensitive to tooling setup. The diameter of the hoses, the diameter of a fittings, and extra filtering can affect pressure. The required tools that are listed in Table 3 were used to develop this test procedure. These tools are suggested and may vary depending on availability and bench configuration.

FT Drawings

Illustration 3	g03866755
FT-2937 (1) Rear Support (12.7x 254x876.3 LG) (2) Gusset (25.4 SQ x 774.7 LG) (3) Front Support (12.7x 127x342.9 LG)

Illustration 4	g03866789
FT-2974 (1) Plate (6.35x 177.8x190.4) (2) Pipe Nipple (3 inch NPT) (3) Pipe Elbow (3 inch NPT) (4) Nipple (3 inch NPT/3 inch ID hose) (5) Clamp (Punch-LOK P18-S) (6) Hose (3 inch ID)

Installation Procedure

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Illustration 5	g03680818

1. Install Tooling (A) on to the test bench.
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   Illustration 6	g03680828

2. Install Tooling (B) to the bottom of the test stand.

   Note: Shim under Tooling (B) as needed to help level the transmission.

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   Illustration 7	g03680846

3. Remove drain plug (1).
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   Illustration 8	g03680861

4. Install Tooling (C) to the transmission.

   Note: Tooling (C) will activate the drain valve, allowing the oil to drain into the test bench bed.

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   Illustration 9	g03680868

5. Use a hoist to install the transmission onto the test bench. The weight of the transmission is approximately 2359 kg (5200 lb).
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   Illustration 10	g03680876

6. Install Tooling (D) to the input yoke.
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7. Install Tooling (E) onto Tooling (D).
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   Illustration 12	g03680897

8. Install Tooling (F) onto Tooling (E).
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   Illustration 13	g03680904

9. Align the input drive shaft and attach to Tooling (F).
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   Illustration 14	g03581501

10. Close and latch the drive shaft guard.
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11. Tighten castle nuts and jack bolts on the test bed.

12. There are two options for draining oil out of drop box:
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    1. Loosen cover (2) on both sides.
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       Illustration 17	g01103408

    2. Remove cover (2) and install Tooling (G).
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    Illustration 18	g03681094

13. Install Tooling (H) to both sides of the transmission to prevent movement during testing.
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    Illustration 19	g03681800

14. Remove covers (3) and (4).
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    Illustration 20	g03681804

15. Remove cover (5).
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    Illustration 21	g03681815
    Left: Controls (in) Right: Controls (out) / TC (out)

16. Install Tooling (J) to the transmission.

    Note: Oil supply on the left internally feeds the Controls and the Torque Converter. The right side may be referred to as either Controls out or TC out. This flow is measured and becomes the Lube supply.

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    Illustration 22	g06411590

17. Install Tooling (K) on Tooling (J) Controls (out) / TC (out).

    Note: Tooling (K) will be used for the TC Block Test.

    Note: This step was left out of the original publication and the photo used is not from the original test. This photo is for reference only and this tooling will not appear anywhere else in the procedure.

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    Illustration 23	g06411602

18. Install Tooling (L) to the transmission.
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    Illustration 24	g03681828
    Controls (in)

19. Install Hose Assembly (6) from pump supply to Tooling (J).

    Note: Oil supply internally feeds the Controls and the Torque Converter.

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    Illustration 25	g03681834
    Controls (out) / TC (out)

20. Install Hose Assembly (7) from Tooling (K) to Flowmeter 1 (in).

    Note: Oil supply on the left internally feeds the Controls and the Torque Converter. The right side may be referred to as either Controls out or TC out. This flow is measured and becomes the Lube supply.

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    Illustration 26	g03681841
    Lube (in)

21. Install Hose Assembly (8) from Flowmeter 1 (out) to Tooling (L).
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    Illustration 27	g03681853
    3447 kPa (500 psi) (9) Speed Clutch

22. Connect a pressure gauge to pressure tap (9).
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    Illustration 28	g03681860
    3447 kPa (500 psi) (10) Directional Clutch

23. Connect a pressure gauge to pressure tap (10).
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    Illustration 29	g03681874
    3447 kPa (500 psi) (11) Supply pressure/Controls (in)

24. Connect a pressure gauge to pressure tap (11).
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    Illustration 30	g03681906
    965 kPa (140 psi) (12) TC (out)

25. Connect a pressure gauge to pressure tap (12).
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    Illustration 31	g03681914
    965 kPa (140 psi) (13) Lube (in)

26. Connect a pressure gauge to pressure tap (13).
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    Illustration 32	g06411611

27. Install Tooling (M) to the transmission.
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    Illustration 33	g06411615

28. Connect Tooling (M) to Tooling (N). Connect Tooling (N) to your power source. Refer to the Tool Operating Manual , NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “Wheel Loaders”.

2. Select “990-24V".

Harness Test

1. Make sure Tooling (M) is properly connected.

2. Use Tooling (N) to perform the harness test.

3. Record the values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Checks

1. If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using Mobil DTE11 oil, warm the oil to 34 °C (95 °F). Maintain this temperature during the entire test.

2. Set the input flow to 76 ± 4 L/min (20 ± 1 US gpm).
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   Illustration 34	g06411923

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 750 ± 20 rpm.

4. Shift the transmission through all gears to eliminate air from the transmission controls.

5. Confirm that there is lube pressure.

   Note: If there is no lube pressure after 30 seconds, stop the test and verify test stand and transmission connections.

6. Confirm the correct clutch engagement with Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	CL 1	CL 2	CL 3	CL 4	CL 5
   N			X
   F1		X			X
   F2		X		X
   F3		X	X
   R1	X				X
   R2	X			X
   R3	X		X

7. With the transmission in NEUTRAL position, measure Lube flow, Main Relief, and Lube pressures.

8. Record the values in Table 8.

9. Confirm the values with Table 7.

   Note: If the values do meet acceptable criteria, stop the test and verify test stand, instrumentation hook-ups, calibration, and/or repair/adjust the transmission.

10. Set the input flow to 189 ± 3.8 L/min (50 ± 1 US gpm).

11. Adjust the input rotation to 2000 ± 20 rpm.

12. Wait until flows and pressures stabilize.

13. Repeat Steps 7 through 9.

Lube Circuit Check

1. Shift the transmission into FORWARD 2 and set the input speed to 1800 ± 20 rpm.

2. Adjust the input flow to achieve a Lube flow of 151 ± 4 L/min (40 ± 1 US gpm).

3. Lube pressure must be 48 ± 14 kPa (7 ± 2 psi).

4. Record the value in Table 9.

Torque Converter Block Check

1. Adjust the input flow to 76 ± 4 L/min (20 ± 1 US gpm). Maintain this flow during this check.

2. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 750 ± 20 rpm.

3. Shift the transmission to FORWARD 1.

4. Use Tooling (K) to block Controls (out) / TC (out) flow temporarily.

   Note: To prevent running the transmission dry, do not block oil flow for more than 10 seconds at a time.

5. The torque converter inlet pressure must be 931 ± 83 kPa (135 ± 12 psi).

6. Open the lube flow.

7. Record the value in Table 10.

Low Idle Checks

1. Set the input flow to 189 ± 4 L/min (50 ± 1 US gpm).

2. Adjust the input rotation to 750 ± 20 rpm.

3. Shift the transmission to FORWARD 1 .

4. Record Lube Flow, Lube, Main Supply, Speed Clutch, and Directional Clutch pressures, and Horse Power Loss in Table 12.

5. Confirm values with Table 11.

6. Shift transmission through FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, and REVERSE 3.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

7. Repeat Steps 2 through 5.

High Idle Checks

1. Set the input flow to 189 ± 4 L/min (50 ± 1 US gpm).

2. Adjust the input rotation to 750 ± 20 rpm.

3. Shift the transmission to FORWARD 1 and increase input rotation to 2000 ± 20 rpm.

4. Record Lube Flow, Lube, Main Supply, TC (in), Speed Clutch, and Directional Clutch pressures, and Horse Power Loss in Table 14.

5. Confirm values with Table 13.

6. Adjust the input rotation to 750 ± 20 rpm.

7. Shift transmission through FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, and REVERSE 3.

   Note: Always shift the transmission back to NEUTRAL when shifting between FORWARD and REVERSE.

8. Repeat Steps 3 through 6.

Clutch Leakage Check

Note: This test is calculations only from data previously collected. This test does not require input rotation or oil flow, and can be completed after all other tests.

1. Make leakage calculations in Table 15.

2. Record the flow results from the High Idle Check in Table 14 into Table 15.

3. Subtract Lube Flow from the Total Pump Flow.

4. The leakage difference between SECOND and THIRD gears or between FORWARD and REVERSE should not exceed 1.2 L/min (0.4 US gpm).

5. The leakage difference between the FIRST, SECOND, and THIRD gear ranges must not exceed 3 L/min (0.8 US gpm) of this arrangement. Reference is 11.4 ± 3 L/min (3 ± 0.8 US gpm).

6. The result is the Total Clutch Leakage.

   Note: Maximum Leakage is 15 L (4 US gal).

Speed Sensor Test

1. Set the input flow to 76 ± 4 L/min (20 ± 1 US gpm).

2. Adjust the input speed to 750 ± 20 rpm.

3. Shift the transmission to FORWARD 2.

4. Record Output Speed 1 and Output Speed 2 in Table 16.

Contamination Control

1. Take an oil sample of the test bench oil supply. Oil contamination must be maximum ISO 16/13.

2. Record the results in Table 17.

3. Remove the transmission from the test bench if the test bench oil supply is within specifications.

Transmission Bench Test Data Sheet

Harness Test

Start Checks

Lube Circuit Check

Torque Converter Block Check

Low Idle Checks

High Idle Checks

Clutch Leakage Check

Speed Sensor Test

Contamination Control