Bench Test Procedure for a 993K Wheel Loader Transmission {3030, 3073} Caterpillar

Tillage

TL2 730 (S/N: LRC1-UP)

Wheel Loader

993K (S/N: LWA1-UP; Z4D1-UP; Z8D1-UP; Z9K1-UP; Z4Z1-UP; Z8Z1-UP)

Introduction

Table 1

Revision	Summary of Changes in REHS3582
05	Added Z8D, Z8Z, and Z9K serial number prefixes.
04	Updated value in Initial Pressure Check Step 9.
03	Standardized.
02	Added Z4D and Z4Z serial number prefixes. Added transmission arrangements 341-2034 and 355-0506 to Table 2.
01	Updated introduction and added Canceled Part Numbers section.

© 2018 Caterpillar All Rights Reserved. This guideline is for the use of Caterpillar 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 special instruction 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 guideline 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 guideline 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
993K	243-1729, 255-9332, 341-2034, 355-0560
993K 2	355-0560, 341-2034

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 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 guideline 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 Test Data

Since conditions vary for each test bench, to 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.

Required Tools

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 Table 3 were used to develop this test procedure.

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1U-9584	Rail As	2
	FT-2937	Support Gp	1
	3B-2968	Bolt	2
	5P-8248	Hard Washer	2
	439-3939	Link Bracket	2
B	1U-9722	Load Binder As	3
C	1U-5798	Drive Adapter Gp	1
	0S-1594	Bolt	4
	3B-4506	Lockwasher	4
D	1U-9131	Drive Adapter (Key)(1) (Key)	1
	1U-9359	Drive Adapter(2)	1
E	9U-7445	Adapter	2
	1U-8304	Fitting	2
	197-3295	Half Flange	4
	8C-9024	Fitting As	2
	6A-5591	Bolt (M12X1.75X25 mm)	8
	6V-4144	Coupler	2
F	9U-7446	Adapter	1
	1U-8301	Fitting	1
	1P-4579	Half Flange	2
	8C-9024	Fitting As	1
	6V-8675	Bolt (M12X1.75X35 mm)	4
	6V-4144	Coupler	1
G	FT-2974	Adapter As(3)	1
	140-5978	Fitting	2
		90 Degree Elbow 3" NPTF	1
	007-6808	Pipe Coupling	1
	1U-9879	Adapter	1
	0S-1594	Bolt (3/8-16X1.00 inch)	3
	3B-4506	Lockwasher	3
H	120-6843	Ball Valve	1
	8C-9024	Fitting As	1
	8C-9025	Quick Coupler	1
J	4C-6818	Pressure Sensor Gp ( 3450 kPa (500.0 psi))	3
	6V-4144	Coupler	3
K	4C-6817	Pressure Gauge ( 690 kPa (100.0 psi))	1
	6V-4144	Coupler	1
L	277-2362	Transmission Analyzer Tool Gp	1
	OR
	277-2362	Transmission Analyzer III Gp	1
	306-0397	Extension Cable (Transmission Analyzer)	1
	9U-7497	Adapter Cable As	1
	1U-9480	Cable Adapter	1
	241-4879	Cable Adapter	1

(1)	This drive adapter is used with the small drive shaft.
(2)	This drive adapter is used with the large drive shaft.
(3)	Item 1 only

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	g03866239

1. Install Tooling (A) on the test bench. Use a suitable support (1) to support the rear of the transmission.
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   Illustration 6	g01796513

2. Use a hoist to install the transmission on the test bench. The weight of the transmission is 2500 kg (5500 lb).
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   Illustration 7	g01796537

3. Install Tooling (B) to the transmission.

   Note: Over-tightening Tooling (B) can jeopardize the tightening ability of the castle nuts on Tooling (A) later in this section.

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   Illustration 8	g01797279

4. Install Tooling (C) to the input yoke.
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   Illustration 9	g01797353

5. Install Tooling (D) to Tooling (C).

   Note: If you are using the small shaft, only the small adapter is needed. If you are using the large drive shaft, use both adapters.

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   Illustration 10	g01797374

6. Align the transmission with the input drive shaft.

7. Connect the input drive shaft to Tooling (D).
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   Illustration 11	g01797393

8. Install the drive shaft guard.
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   Illustration 12	g03802221

9. Tighten all four castle nuts and jack bolts.

10. Tighten Tooling (B) to prevent movement of the transmission during testing.
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    Illustration 13	g01797399

11. Remove cover (2).
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    Illustration 14	g01797433

12. Install Tooling (E).
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    Illustration 15	g01797494

13. Remove cover (3).
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    Illustration 16	g01797574

14. Install Tooling (E).
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    Illustration 17	g01797933

15. Remove cover (4).
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    Illustration 18	g01797954

16. Install Tooling (F).
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    Illustration 19	g01797995

17. Remove cover (5).
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    Illustration 20	g01815820

18. Install Tooling (G).
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    Illustration 21	g01816037

19. Install a suitable hose assembly (6) to Tooling (G) to drain the transmission sump.
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    Illustration 22	g01815894
    (7) Supply oil

20. Install hose assembly (7) from the pressurized flow meter to Tooling (E).

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

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    Illustration 23	g01815965
    (8) Torque converter oil flow

21. Install Tooling (H) to Tooling (E). Install hose assembly (8) from Tooling (H) to No. 2 flow meter inlet.

    Note: The No. 2 flow meter will measure the torque converter outlet oil that is returning to the test bench.

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    Illustration 24	g01816015
    (9) Lube oil

22. Install hose (9) from the No. 2 flow meter outlet to Tooling (F).
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    Illustration 25	g01816070
    (10) Speed clutch pressure tap "P1" (11) Direction clutch pressure tap "P2"

23. Install Tooling (J).
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    Illustration 26	g01816119
    (12) Torque Converter Inlet Pressure

24. Install Tooling (J).
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    Illustration 27	g03866289
    (13) Lube Pressure

25. Install Tooling (K).

    Note: Tooling (K) measures transmission lubrication pressure.

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    Illustration 28	g01816734

26. Connect Tooling (L) to the transmission.
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    Illustration 29	g01819016

27. Connect Tooling (L) to a suitable location.

28. Cover the transmission with a suitable clean cover.
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    Illustration 30	g00877510
    Tooling (L)

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    Illustration 31	g01457869
    Tooling (L)

29. Connect Tooling (L) to a power source. Refer to Tool Operating Manual, NEHS0644 or Tool Operating Manual, NEHS0996 for the correct operating instructions.

Test procedure

TA3 Navigation

1. Select “Wheel Loader”.

2. Select “993K-24V”.

Harness Test (TA3 only)

1. Make sure that the harness is properly connected.

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

3. Record the values in Table 7.

   Note: Do not continue testing until Harness Test passes.

Solenoid Test (TA2 only)

1. Make sure that the harness is properly connected.

2. Use Tooling (L) to perform the solenoid test.

3. Record the values in Table 7.

   Note: Do not continue testing until Solenoid Test passes.

Start Checks

Note: Refer to Testing and Adjusting, KENR5816, "993K Wheel Loader Power Train" for the correct adjustments.

1. If you are using SAE 10W oil, warm the oil to 50 °C (125 °F). If you are using MobilDTE11 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 32	g02720621

3. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 750 ± 10 rpm.

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

5. 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

6. The lubrication pressure must be 28 ± 7 kPa (4 ± 1 psi).

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

7. Record the value in Table 8.

8. Stop the input rotation.

9. Stop the input flow.

Initial Pressure Check

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Illustration 33	g01820395

1. Remove test port (10).

2. Remove test port (11).

3. Remove cover (13) as a unit.
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   Illustration 34	g01822299

4. Remove adapters (14).
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   Illustration 35	g01820457

5. Install test ports (10) and (11) that were removed from cover (13).

6. Install Tooling (J) to ports (10) and port (11).
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   Illustration 36	g01820474

7. Remove load piston plug (15).

8. Use a suitable clean cover to cover the transmission.

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

10. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 750 ± 10 rpm.

11. The "P1" pressure must be 585 ± 35 kPa (85 ± 5 psi).

12. Record the value in Table 9.

13. Stop the input rotation.

14. Stop the input flow.

15. Install load piston (15).

16. Remove test port (10) and remove test port (11).

17. Install adapters (14).

18. Install cover (13).

19. Install test port (10) and test port (11) on cover (13).

20. Connect Tooling (J) to test port (10) and test port (11).

Torque Converter Inlet Ratio Valve

1. Adjust the input flow to 114 ± 4 L/min (30 ± 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 ± 10 rpm.

3. Shift the transmission to FORWARD 1.

4. Momentarily block the lube flow.

5. The torque converter inlet pressure must be 1006 ± 55 kPa (145 ± 8 psi).

6. Open the lube flow.

7. Record the value in Table 10.

Lube Circuit Check

1. Adjust the input flow until the lube flow is 152 ± 4 L/min (40 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 900 ± 30 rpm.

3. Shift the transmission to the FORWARD 2 position.

4. The lubrication pressure must be within 10 kPa (2 psi) of the average for this arrangement. Reference is 55 ± 14 kPa (8 ± 2 psi).

5. Record the value in Table 11.

Clutch Leakage Check

1. Adjust the input flow to 201 ± 4 L/min (53 ± 1 US gpm). Maintain this flow during this check.

2. Adjust the input rotation to 700 ± 30 rpm.

3. Shift the transmission to the FORWARD 1 position.

4. Adjust the input rotation to 1900± 10 rpm.

5. Record the input flow in Table 12.

6. Record the lube flow in Table 12.

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

8. Record the calculation in Table 12.

9. Adjust the input rotation to 700 ± 30 rpm.

10. Shift the transmission through positions FORWARD 2, FORWARD 3, REVERSE 1, REVERSE 2, REVERSE 3, and NEUTRAL. Repeat Steps 4 through 9 for each gear range.

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

11. The leakage difference between SECOND and THIRD gears or between FORWARD and REVERSE should not exceed 2.3 L/min (0.61 US gpm).

12. The difference in lube flow between the FIRST, SECOND, and THIRD gear ranges must not exceed 3.0 L/min (0.80 US gpm) of the average for this arrangement. Reference is 6.4 ± 3.0 L/min (1.70 ± 0.80 US gpm).

13. Record the calculations in Table 12.

14. Stop the input rotation.

15. 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	1900 ± 10 rpm	750 ± 10 rpm
Input Flow	201 ± 4 L/min (53 ± 1 US gpm)	114 ± 4 L/min (30 ± 1 US gpm)
Minimum Lube Flow	174 L/min (46 US gpm)	95 L/min (25 US gpm)
Pressures
"P1" Initial(1)	-	586 ± 35 kPa (85 ± 5 psi)
P1	2551 ± 138 kPa (370 ± 20 psi)	2206 kPa (320 psi) min
P2	P1 − 379 ± 55 kPa P1 − 55 ± 8 psi	P1 − 379 ± 55 kPa P1 − 55 ± 8 psi
P3(2)	-	1000± 55 kPa (145 ± 8 psi)
Lube(3)	83 ± 7 kPa (12 ± 1 psi)	35 ± 7 kPa (5 ± 1 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.

Solenoid Test

Table 7

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

Start Checks

Table 8

Lubrication Pressure	Input Speed (750 ± 10 rpm)	_______kPa _______(psi)
	Input Flow 114 ± 4 L/min (30 ± 1 US gpm)

Initial Pressure Check

Table 9

Initial Pressure	Input Speed (750 ± 10 rpm)	_______kPa _______(psi)
	Input Flow 114 ± 4 L/min (30 ± 1 US gpm)

Torque Converter Inlet Ratio Valve

Table 10

Pressure for the Torque Converter Inlet Ratio Valve	Input Speed (750 ± 10 rpm)	_______kPa _______(psi)
	Input Flow 114 ± 4 L/min (30 ± 1 US gpm)

Lube Circuit Check

Table 11

Lube Circuit Check		Gear Range FORWARD 2
		Input Speed (900 ± 30 rpm)
		Lube Flow 152 ± 4 L/min (40 ± 1 US gpm)
Average Lubrication Pressure Of Arrangement	_______kPa _______(psi)	Lubrication Pressure	_______kPa _______(psi)

Clutch Leakage Check

Table 12

Clutch Leakage Check		Input Speed (1900 ± 10 rpm)
		Input Flow 201 ± 4 L/min (53 ± 1 US gpm)
Gear Range	1F	2F	3F	1R	2R	3R	N
Input Flow	______	______	______	______	______	______	______
Lube Flow	______	______	______	______	______	______	______
Leakage	______	______	______	______	______	______	______

ISO Particle Count

Table 13

ISO Particle Count

Sample the test bench oil supply.ISO 4406

________/________Particle Count

Table 14

______________________________________ Technician

______________________________________ Supervisor