Bench Test Procedure For A 994D, 994F, 994H, And 994K Wheel Loader Transmission {3030, 3073} Caterpillar

Wheel Loader

994D (S/N: 3TZ1-UP)

994F (S/N: 4421-UP)

994H (S/N: DWC1-UP)

994K (S/N: MM91-UP; MRK1-UP; SMX1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3490
06	Added (S/N: SMX).
05	Added (S/N: MM9)
04	Updated Table 4. Changed Introduction Section
03	Added (S/N: MRK) and 388-2730
02	Updated Table 6. Standardized.

© 2018 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 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.

Table 2

Machine Model	Transmission Arrangement
994D	153-7520
994F	239-8137
994H	353-4739
994K	388-2730

Canceled Part Numbers and Replaced Part Numbers

This document may not 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 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 the product 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, the specifications, and the 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 arrangements is collected and stored. averages from each transmission arrangements are often used to compare values on portions of transmission test. 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 hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in the table were used to develop this test procedure. These tools are suggested and may very depending on availability and bench configuration.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	312-4124	Stand Group	1
B	7X-2563	Bolt	6
	8T-4123	Washer	6
C	1U-8847	Drive Adapter	1
	6V-3532	Bolt	4
	8T-3282	Washer	4
D	1U-9131	Drive Adapter(1)	1
	1U-9359	Drive Adapter(2)	1
E	1P-5575	Adapter	1
	1U-8304	Fitting	1
	8C-9025	Fitting	1
F	9U-7445	Adapter	1
	1U-8304	Fitting	1
	8C-9024	Fitting	2
	8C-9025	Quick Coupler	1
	005-8615	Adapter	1
	120-6843	Ball Valve	1
G	9U-7445	Adapter	1
	197-3295	Half Flange	2
	1U-8304	Fitting	1
	1L-4031	Tee	1
	005-8615	Adapter	1
	3B-6498	Elbow	1
	8C-9024	Fitting	2
H	5P-4481	Adapter	1
	5L-5502	Tee	1
	6B-5072	Reducer Bushing	1
	6V-3966	Fitting	1
	007-0950	Bushing Adapter	1
	004-5703	Bushing Adapter	1
	8C-9024	Fitting	1
J	6V-3966	Fitting	1
	6V-3297	Tee Fitting	1
K	6V-3965	Fitting	2
L	6S-7744	Adapter	1
M	3B-7282	Pipe	2
	6V-4142	Fitting	2
N	459-4084	Adapter Cable As	1
	306-0397	Extension Cable	1
P	277-2362	Transmission Analyzer III Gp	1
Q(3)	4C-9910	Portable Hydraulic Tester	2
R(3)	8T-0855	Pressure Gauge	6
	6V-4144	Quick Connect Coupler	6
S(3)	8T-0854	Pressure Gauge	4
	6V-4144	Quick Connect Coupler	4

(1)	This Drive adapter is used with the small drive shaft.
(2)	This Drive Adapter is used with the large drive shaft.
(3)	Optional Tooling if needed with Test Bench.

Installation Procedure

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Illustration 3	g01533893

1. Remove cover (1) for the duration of the test.
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   Illustration 4	g01518673

2. Install Tooling (A) on the test bench and tighten the fasteners.
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   Illustration 5	g01518786

3. Use the hoist to install the transmission to Tooling (A). The weight of the transmission and the drop box as an assembly is 3062 kg (6750 lb).
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   Illustration 6	g01518817

4. Install Tooling (B) to secure the transmission to Tooling (A).
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   Illustration 7	g01520805

5. Install Tooling (C) to the Input Shaft on the front of the transmission.
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   Illustration 8	g01520807

6. Install Tooling (D) to Tooling (C).
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   Illustration 9	g01520810

7. Install the Input Drive Shaft to Tooling (D).
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   Illustration 10	g01520818

8. Install the drive shaft guard.
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   Illustration 11	g01520820
   (2) Main Oil Supply Port

9. Remove the cover from port (2).
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   Illustration 12	g01520823

10. Install Tooling (E) to port (2).
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    Illustration 13	g01520830
    (3) Torque Converter Inlet Oil

11. Remove the cover from port (3).
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    Illustration 14	g01520842

12. Install Tooling (F) to port (3).
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    Illustration 15	g01521262
    (4) Torque Converter Outlet Oil (Lubrication Oil)

13. Remove the cover from port (4).
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    Illustration 16	g01521266

14. Install Tooling (G) to port (4).
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    Illustration 17	g01521778
    (5) Lubrication Oil

15. Remove the plug from port (5).
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    Illustration 18	g01521792

16. Install Tooling (H) to port (5).
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    Illustration 19	g01521801
    (6) Input Transfer Gear Lubrication

17. Remove the plug from port (6).
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    Illustration 20	g01521825

18. Install Tooling (J) to port (6).
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    Illustration 21	g01521862
    (7) Transmission Lubrication Pressure

19. Remove fitting from port (7).
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    Illustration 22	g01521865

20. Install Tooling (K) to port (7).
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    Illustration 23	g01521961
    (8) Main Supply Oil Pressure (9) Torque Converter Oil Pressure (Lubrication Oil)

21. Remove fittings from ports (8) and (9).
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    Illustration 24	g01521967

22. Install Tooling (K) to port (8) and Install Tooling (L) to port (9).
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    Illustration 25	g01521971
    (10) Access Cover

23. Remove access cover (10).
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    Illustration 26	g01521978
    (11) Speed Clutch Pressure (P1)

24. Remove plug (11).
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    Illustration 27	g01521981

25. Install Tooling (M) to the valve ports.
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    Illustration 28	g01522177
    (12) Main Supply Oil

26. Connect Hose Assembly (12) from the pressurized flow meter to Tooling (E).

    Note: The flow meter will measure the flow of the supply oil.

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    Illustration 29	g01522194
    (13) Torque Converter Inlet Oil

27. Connect Hose Assembly (13) from Tooling (F) to the No. 2 flow meter inlet.

    Note: The No. 2 flow meter will measure the Converter Oil that is returning to the test bench.

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    Illustration 30	g01522202
    (14) Lubrication Oil

28. Connect Hose Assembly (14) from the No. 2 flow meter outlet to Tooling (G).
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    Illustration 31	g01523071
    (15) Lubrication Oil for the Drop Box

29. Install one end of Hose Assembly (15) to Tooling (G).
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    Illustration 32	g01522204
    (15) Drop Box (Lubrication Oil)

30. Install one end of Hose Assembly (15) to Tooling (H).
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    Illustration 33	g01522214
    (16) Input Transfer Gear Lubrication

31. Install one end of Hose Assembly (16) to Tooling (L).
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    Illustration 34	g01522211
    (16) Input Transfer Gear Lubrication

32. Install one end of Hose Assembly (16) to Tooling (J).
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    Illustration 35	g01522224
    (17) Input Transfer Gear (Lubrication Pressure)

33. Install Pressure Gauge (17) to Tooling (J).
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    Illustration 36	g01522236
    (18) Main Supply Pressure

34. Install Pressure Gauge (18) to Tooling (K).
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    Illustration 37	g01522242
    (19) Lubrication Oil Pressure

35. Install Pressure Gauge (19) to Tooling (G).
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    Illustration 38	g01522252
    (20) Transmission Lubrication Pressure

36. Install Pressure Gauge (20) to Tooling (K).
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    Illustration 39	g01522255
    (21) Drop Box Lubrication Pressure

37. Install Pressure Gauge (21) to Tooling (H).
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    Illustration 40	g01522257
    (22) Torque Converter Inlet Oil Pressure (P3)

38. Install Pressure Gauge (22) to Tooling (F).
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    Illustration 41	g01522261
    (23) Speed Clutch Pressure (P1)

39. Install Pressure Gauge (23) to Tooling (M).
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    Illustration 42	g01522877
    (24) Direction Clutch Pressure (P2)

40. Install Pressure Gauge (24) to Tooling (M).
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    Illustration 43	g01522883

41. Install Tooling (N) to the transmission and make sure that Tooling (N) has a sufficient ground.
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    Illustration 44	g01457869
    Tooling (P)

42. Connect Tooling (N) to Tooling (P). Refer to the Tool operating manual, NEHS0996 for the correct operating instructions.

Test Procedure

TA3 Navigation

1. Select “Wheel Loaders”.

2. Select “994D-24V” or “994F-24V”.

Harness Test

1. Make sure that Tooling (N) is properly connected.

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

3. Record the values in Table 7.

   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 for the duration of the test.

2. Adjust the input flow to 114 ± 4 L/min (30 ± 1 US gpm).
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   Illustration 45	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1050 ± 10 rpm.

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

5. Shift the transmission until all clutch fills are consistent.

6. The lubrication pressure must be 21 ± 14 kPa (3 ± 2 psi).

   Note: If there is no lube pressure after 30 seconds, stop input rotation and check connections on transmission and test bench.

7. Record lube pressure in Table 8.

8. Verify that the active clutches are correct for each gear range. Refer to Table 4.
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   Table 4

   Clutch Assignment Check
   Gear	Directional Clutches		Speed Clutches
   	Cl 1 (P1)	Cl 2 (P2)	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

9. Stop the input rotation.

10. Stop the input flow.

Initial Pressure Check

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Illustration 46	g01526052

1. Remove load piston plug (25).

2. Cover the transmission with a clean rag.

3. Adjust the input flow to 114 ± 4 L/min (30 ± 1 US gpm).

4. With the transmission in the neutral position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 1050 ± 10 rpm.

5. The P1 pressure (23) must be 530 ± 34 kPa (77 ± 5 psi).

6. Record the value in Table 9.

7. Stop the rotation and input flow.

8. Install the load piston plug (25).

Torque Converter Inlet Ratio Valve Check

1. Adjust the input flow to 151 ± 4 L/min (40 ± 1 US gpm).

2. Adjust the input rotation to 1050 ± 10 rpm.

3. Shift the transmission to the FORWARD 1.

4. Momentarily block the lubrication flow with Tooling (F).

5. The torque converter inlet pressure (P3) must be 951 ± 55 kPa (138 ± 8 psi).

6. Open the lubrication flow.

7. Record the value in Table 10.

Lubrication Circuit Check

1. Adjust the input flow until lube flow of 151 ± 4 L/min (40 ± 1 US gpm) is achieved.

2. Adjust the input rotation to 1050 ± 10 rpm.

3. Shift the transmission to the FORWARD 2.

4. Lubrication pressure must be within ± 9 kPa (± 1.3 psi) of the average for this transmission arrangement. Reference is 62 ± 14 kPa (9 ± 2 psi).

5. Record the lubrication pressure in Table 11.

Clutch Leakage Check

1. Adjust the input flow to 189 ± 4 L/min (50 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 700 ± 10 rpm.

3. Shift the transmission to the FORWARD 1.

4. Adjust the input rotation to 1800 ± 10.

5. Record the input flow in Table 12.

6. Record the lubrication flow in Table 12.

7. The leakage is obtained by subtracting the lubrication flow from the input flow.

8. Record the calculation in Table 12.

9. Adjust the input rotation to 700 ± 10 rpm.

10. Repeat Steps 4 through 9 for each gear range.

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

11. The leakage difference between SECOND and THIRD gears or between FORWARD and REVERSE should not exceed 1 L (0.25 US gal).

12. Record the calculations in Table 12.

13. Stop the input rotation.

14. Stop the input flow.

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 13.

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

Transmission Bench Test Data Sheet

Table 5

CATERPILLAR	Transmission Bench Test Data Sheet	Test Date:_______
		Model:_______
Work Order:_______		Serial No.:_______

Table 6

Specifications
Description	High Idle	Low Idle
Input Speed	1800 ± 10 rpm	1050 ± 10 rpm
Input Flow	189 ± 1 L/min (50 ± .25 US gpm)	114 ± 1 L/min (30 ± .25 US gpm)
Minimum Lubrication Flow	95 L/min (25 US gpm)	38 L/min (10 US gpm)
Pressures
P1 Initial(1)	-	531 ± 34 kPa (77 ± 5 psi)
P1	2861 ± 55 kPa (415 ± 8 psi)	2654 kPa (385 psi)min
P2	P1 - 379 kPa (55 psi)	P1 - 379 kPa (55 psi)
P3(2)	-	951 ± 55 kPa (138 ± 8 psi)
Lubrication(3)	-	62 ± 14 kPa (9 ± 2 psi)

(1)	The Load Piston Plug is removed and the transmission is in the NEUTRAL position.
(2)	The flow for the torque converter outlet is restricted.
(3)	The transmission is in FORWARD 2.

Harness Test

Table 7

Harness Test	Solenoid 1	Solenoid 2	Solenoid 3	Solenoid 4	Solenoid 5
	_______ ohms	_______ ohms	_______ ohms	_______ ohms	_______ ohms

Start Checks

Table 8

Lubrication Pressure

Input Speed (1050 ± 10 rpm) Input Flow 114 ± 4 L/min (30 ± 1 US gpm)

_______kPa _______(psi)

Initial Pressure Check

Table 9

Initial Pressure

Input Speed (1050 ± 10 rpm) Input Flow 114 ± 4 L/min (30 ± 1 US gpm)

_______kPa _______(psi)

Torque Converter Inlet Ratio Valve Check

Table 10

Torque Converter Inlet Ratio Valve Pressure

Input Flow 151 ± 4 L/min (40 ± 1 US gpm)

_______kPa _______(psi)

Lubrication Check (Low Idle)

Table 11

Lubrication Check	Low Idle (1050 ± 10 rpm)
Gear	Lubrication Pressure	Lubrication Flow
FORWARD 2	_______kPa _______(psi)	_______L/min _______(gpm)

Clutch Leakage Check

Table 12

Clutch Leakage Check		Input Speed (1800 ± 10 rpm) Input Flow 189 ± 4 L/min (50 ± 1 US gpm)
Gear Range	N	F1	F2	F3	R1	R2	R3
Input Flow	_____	_____	_____	_____	_____	_____	_____
Lube Flow	_____	_____	_____	_____	_____	_____	_____
Leakage	_____	_____	_____	_____	_____	_____	_____

Contamination Control

Table 13

ISO Particle Count

Sample the test bench oil supply. *ISO 4406 is 16/13 or better

________/________Particle Count

Table 14

______________________________________ Technician

______________________________________ Supervisor