Bench Test Procedure for a 834K and 836K and 988K Wheel Loader Transmission {3030, 3065, 3073, 3139} Caterpillar

Landfill Compactor

836K (S/N: T6X1-UP; L6Z1-UP; LWZ1-UP; TWZ1-UP)

Wheel Dozer

834K (S/N: TW41-UP; L4Y1-UP; LWY1-UP; TWY1-UP)

Wheel Loader

988K (S/N: T8E1-UP; L8X1-UP; LWX1-UP; TWX1-UP)

988K XE (S/N: E8X1-UP)

Introduction

© 2018 Caterpillar All Rights Reserved. This guideline 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.

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.

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 "NOT" 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 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 hose, the diameter of a fitting, and additional filtering can affect pressure. The required tools that are listed in Table 3 were used in order to develop this test procedure.

Installation Procedure

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Illustration 3	g03380144

1. Install Tooling (A) to the test bed.
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   Illustration 4	g03416860

2. Install Tooling (D).
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   Illustration 5	g03380153

3. Use a hoist to install the transmission on the test bench to Tooling (A) . The weight of the transmission is 1701 kg (3750 lb.).

   Note: Use 6V-3669 Bolt to hold transmission in place. Refer to Illustration 5.

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   Illustration 6	g03380363

4. Install Tooling (B) to the input yoke on transmission.
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   Illustration 7	g03416893

5. Using the hoist and pry bars, slide transmission forward to align with the drive shaft.
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   Illustration 8	g03380763

6. Connect Tooling (C) to Tooling (B).
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   Illustration 9	g03380431

7. Close and latch the drive shaft guard.
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   Illustration 10	g03416909

8. Tighten all four Castle Nuts and Jack Bolts.
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   Illustration 11	g03381185
   421-5663 Lifting Eye Assembly on front and 369-5916 Lifting Eye Assembly on rear.

9. Install Tooling (D) to the transmission.
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   Illustration 12	g03381268

10. Install the chains and Tooling (D). Tighten ratchet binders to prevent movement of the transmission during the testing process.
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    Illustration 13	g03381455
    Sump

11. Remove the cover plate (1).
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    Illustration 14	g03382367

12. Remove the filter assembly (2).
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    Illustration 15	g03382482

13. Remove the drain plug assembly (3).
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    Illustration 16	g03382845
    Controls (In)

14. Remove the plug and install Tooling (E).
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    Illustration 17	g03384066
    Controls (Out)

15. Remove the plug and install Tooling (F).
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    Illustration 18	g03384057
    Lube (In)

16. Remove the cover and install Tooling (G).
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    Illustration 19	g03382867
    Main pump supply

17. Connect Hose Assembly (4) from Pressurized Flowmeter (Out) to Tooling (H).
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    Illustration 20	g03384105

18. Connect Hose Assembly (5) from Tooling (H) to Flowmeter 2 (In).
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    Illustration 21	g03384432
    Controls (In)

19. Connect Hose Assembly (6) from Flowmeter 2 (Out) to Tooling (E).
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    Illustration 22	g03384456
    Controls (Out)

20. Connect Hose Assembly (7) from Tooling (F) to Flowmeter 3 (In).

21. Connect a Hose Assembly from Flowmeter 3 (Out) back to the tank.
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    Illustration 23	g03384126

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    Illustration 24	g03389183

22. Connect Hose Assembly (8) from Tooling (H) to Tooling (J) Load Sensing Valve (In).
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    Illustration 25	g03389740

23. Connect Hose Assembly (9) from Tooling (J) (Out) to Flowmeter 4 (In).
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    Illustration 26	g03384106
    Lube (In)

24. Connect Hose Assembly (10) from Flowmeter 4 (Out) to Tooling (G).
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    Illustration 27	g03384415
    Lube

25. Connect a pressure gauge to pressure tap (11).
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    Illustration 28	g03388451
    (12) No. 6 clutch (13) No. 5 clutch (14) No. 4 clutch (15) No. 3 clutch (16) No. 2 clutch (17) No. 1 clutch

26. Connect pressure gauges to pressure taps (12-17).
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    Illustration 29	g03387273

27. Connect Tooling (M) to the clutch solenoids.
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    Illustration 30	g03386982

28. Connect Tooling (M) Harness to Analyzer.

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

Test Procedure

TA3 Navigation

1. Select "Wheel Loaders", or "Wheeled Tractors".

2. Select “988K - 24V”, "834K - 24V", "836K - 24V".

   Note: Select the proper program in TA3, the 836K model does not have Clutch 4.

Harness Test

1. Make sure the harness is properly connected.

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

3. Record values in Table 6.

   Note: Do not continue testing until Harness Test passes.

Start Checks

Note: Refer to Testing and Adjusting, KENR6488, "988K Wheel Machine Systems" for the correct adjusting procedures.

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 95 L/min (25 US gpm). Maintain this flow during this check.

3. Adjust Tooling (J) until a split flow of 53 L/min (14 US gpm) Controls (In) and 42 L/min (11 US gpm) Lube (In) is achieved.
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   Illustration 31	g02720621

4. With the transmission in the NEUTRAL position, rotate the input shaft in a counterclockwise direction. Adjust the input rotation to 750 ± 35 rpm.

5. The lubrication pressure must be a minimum of 41kPa (6 psi).

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

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

7. Confirm the correct clutch engagement in Table 4.
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   Table 4

   Clutch Engagement Check
   Gear	CL 1	CL 2	CL 3	CL 4	CL 5	CL 6
   N			X
   F1		X				X
   F2		X			X
   F3		X		X
   F4		X	X
   R1	X					X
   R2	X				X
   R3	X			X
   R4	X		X

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

Lube Circuit Check

1. Adjust the input flow to 197 L/min (52 US gpm). Maintain this flow during this check.

2. Adjust Tooling (J) until a split flow of 87 L/min (23 US gpm) Controls (In) and 110 L/min (29 US gpm) to Lube (In) is achieved.

3. Adjust the input rotation to 750 ± 35 rpm.

4. Shift the transmission to FORWARD 3.

5. Adjust the input rotation to 1250 ± 35 rpm.

6. The lubrication pressure must be 97 ± 34 kPa (14 ± 5 psi).

7. Record the value in Table 7.

Low Idle Checks

1. Adjust the input flow to 95 L/min (25 US gpm). Maintain this flow during this check.

2. Adjust Tooling (J) until a split flow of 53 L/min (14 US gpm) Controls (In) and 42 L/min (11 US gpm) to Lube (In) is achieved.

3. Main pump supply should be 2551 ± 138 kPa (370 ± 20 psi). The Lube pressure should be 62 ± 21 kPa (9 ± 3 psi).

4. Adjust the input rotation to 750 ± 35 rpm.

5. Shift the transmission to the FORWARD 1 position.

6. Record Clutch Pressures in Table 9.

7. Verify Clutch Pressures with Table 8.

8. Record Controls (in) from Flowmeter 2 in Table 10.

9. Record Controls (out) from Flowmeter 3 in Table 10.

10. Subtract FM3 Value from FM2 Value and Record Leakage Results in Table 10.

11. Verify Clutch Leakage with Table 10.

12. Record Horse Power Loss in Table 11.

13. Verify Horse Power Loss with Table 11.

14. Shift the transmission through all gears FORWARD 2, FORWARD 3, FORWARD 4, NEUTRALREVERSE 1, REVERSE 2, REVERSE 3, and REVERSE 4. Repeat Steps 6 through 13.

    Note: Always shift back to Neutral when shifting between Forward and Reverse.

15. Shift transmission back to Neutral.

High Idle Checks

1. Adjust the input flow to 197 L/min (52 US gpm). Maintain this flow during this check.

2. Adjust Tooling (J) until a split flow of 87 L/min (23 US gpm) Controls (In) and 110 L/min (29 US gpm) to Lube (In) is achieved.

3. Main pump supply should be 2896 ± 138 kPa (420 ± 20 psi). The Lube pressure should be 97 ± 21 kPa (14 ± 5psi).

4. Adjust the input rotation to 750 ± 35 rpm.

5. Shift the transmission to the FORWARD 1 position.

6. Adjust the input rotation to 1250 ± 35 rpm.

7. Record Clutch Pressures in Table 13.

8. Verify Clutch Pressures with Table 12.

9. Record Controls (in) from Flowmeter 2 in Table 14.

10. Record Controls (out) from Flowmeter 3 in Table14.

11. Subtract FM3 Value from FM2 Value and Record Leakage Results in Table 14.

12. Verify Clutch Leakage with Table 14.

13. Record Horse Power Loss in Table 15.

14. Verify Horse Power Loss with Table 15.

15. Adjust the input rotation to 750 ± 35 rpm.

16. Shift the transmission through all gears FORWARD 2, FORWARD 3, FORWARD 4, NEUTRALREVERSE 1, REVERSE 2, REVERSE 3, and REVERSE 4. Repeat Steps 6 through 15.

    Note: Always shift back to Neutral when shifting between Forward and Reverse.

17. Shift transmission back to Neutral.

Speed Sensor Test

Note: There are two output and one input speed sensors hat must be identified and tested.

1. Adjust the input rotation to 750 ± 35 rpm.

2. Shift the transmission to FORWARD 1.

3. Connect Tooling (N) to output speed sensor 1 and record in Table 17.

4. Connect Tooling (N) to output speed sensor 2 and record in Table 17.

5. Connect Tooling (N) to input speed sensor and record in Table 17.

6. Shift the transmission to Forward 2.

7. Connect Tooling (N) to output speed sensor 1 and record in Table 17.

8. Connect Tooling (N) to output speed sensor 2 and record in Table 17.

9. Connect Tooling (N) to input speed sensor and record in Table 17.

10. Verify the test results with the values 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 18.

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

Transmission Bench Test Data Sheet

Harness Test

Lube Circuit Check

Low Idle Checks

High Idle Checks

Speed Sensor Test

ISO Particle Count