Caterpillar Motor Grader Series 24 Technician ChecklistEngine ; Torque Converter (TC) Removal and Installation{0372, 0374, 1000, 1003, 1003, 3101, 3101} Caterpillar

Caterpillar Motor Grader Series 24 Technician ChecklistEngine & Torque Converter (TC) Removal and Installation{0372, 0374, 1000, 1003, 1003, 3101, 3101}

Usage:

24H 7KK

Motor Grader:: 24H (S/N: 7KK1-UP); 24M (S/N: B9K1-UP; B931-UP)

Introduction

These checks are required for component removal and installation. Initial check after completion.

Note: Service literature procedures, specific to the model and serial number, must be used in this process. The checklist does not substitute procedures for the procedures given in the service literature.

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Table 1
Customer Name/ Location	Machine Unit Number	Machine Serial Number	Machine Service Meter Hours	Work Order Number
/

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Table 2
Tracking Data	Engine Removed	Engine Installed	T/C Removed	T/C Installed
Serial Number
CID Number ⁽¹⁾
Source/Rebuilder ⁽²⁾

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^( 1 )	CID (Component Identification) is the number assigned to the component by the user/dealer.
^( 2 )	Suorce/Rebuilder is either NEW, REMAN, DLR (Dealer Rebuilt), or CUST (Customer Rebuilt).

Checklist

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Table 3

1.		Record Complaint:


2.		Pre-repair contamination control.
		A.	High-pressure wash the rear half of the motor grader to remove all dirt/debris.
		B.	Maintain a well-organized work area and plan to contain all fluid spills.
		C.	Cover components with plastic or keep in containers until installation to keep clean.
		D.	Verify new parts cleanliness. Assure they are cleaned & capped/protected against dirt.

3.		Investigate engine and torque divider history or failure cause, if appropriate.
		A.	Question the operator on application, operating conditions, and history. Review SOS history.
		B.	Review engine and transmission ECM's for detected faults – record in work order folder.
		C.	Take SOS Sample refer to: Contamination Control Guidelines, SEBF8482, "Obtaining Oil Sample for Analysis". Drain the engine and torque converter oil reservoirs and visually check oil for water, coolant, or debris contaminants..
		D.	Remove/inspect system filters/screens and save any contamination evidence.

4.		If the torque converter failed generating metal/debris, remove, clean, and inspect/repair the transmission and transfer gears. Clean all vulnerable oil system screens/components (reference the System Operations manual). Use the Caterpillar R&I checklists as needed.

5.		High-pressure wash the machine area around the engine and torque converter, before and after removal.

6.		Cover and cap all cleaned and reused components/lines until installed to prevent dirt entry. Cover all removed component cores with plastic sheets until shipping covers are available.

7.		Inspect drive shaft splines and U-joints for wear/damage. Refer to Reuse And Salvage Guidelines, SEBF8126, "Universal Joints and Drive Shafts". Spline tooth wear limit is 0.2 mm (0.008 inch).

8.		Inspect engine mounts and machine frame for stripped threads, cracks, or deformation. Repair/replace and paint as needed.

9.		Inspect TC and transmission filter bypasses for correct operation.

10.		Install a 6-micron "clean-up" filter in the torque converter system. Use the clean-up filters for at least 8 hours operation time.						Filter part number:

11.		Inspect and clean or replace system hoses/tubes. Clean with CAT hose cleaner group. Refer to Tool Operating Manual, NEHS0643, "Using the 233-7191, 233-7192, 233-7193 and 265-4959 hose cleaning groups" and Contamination Control Guidelines, SEBF8485, "Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field Applications". Use new clamps (torque to spec), o-ring seals, and gaskets.

12.		Inspect/replace electrical connectors and harnesses for loose pins, brittleness, and fatigue. Replace the engine/torque converter wire harness every rebuild life cycle.

13.		Install new or rebuilt torque converter oil cooler, and oil pump.

14.		Install cleaned/repaired or new radiator cores, and a rebuilt/new fan drive.

15.		Clean/protect all mounting surfaces and exposed cavities of the replacement components.

16.		Transfer all covers/plugs to the removed component cores and pack into shipping containers to prevent damage and dirt entry. Tag with completed Cat dealer core tag.

17.		Use new bolts/u-joints to install the main drive shafts. Existing bolts cannot be reused.

		Bolt Torque			Specification			Actual
		Main Shaft U-Joint

18.		Clean/replace the primary air filters. Replace secondary air filters. Clean the pre-cleaners. Reset air filter restriction indicator. Insure air induction system integrity (before turbocharger).

19.		Prelube the engine and fill the torque converter with oil meeting ISO --/16/13 cleanliness standard. Prime the fuel system before starting.

20.		Check engine, torque converter, and transmission speeds and pressures. Refer to procedures detailed in the Testing and Adjusting manuals.

			Engine Speed			Torque Converter			Transmission
			Low Idle	High Idle	Stall	Outlet Relief Pressure	Park Brake Release Pressure	Lock up clutch max pressure	Pump Pressure	Lube Pressure
	Specification
	Test
	4000 Hr Check

21.		Before releasing machine, test the torque converter system oil for cleanliness. Kidney-loop filtration may be required to achieve ISO cleanliness level of --/18/15 refer to Contamination Control Guidelines, SEBF8462, "Procedure for Filtering the Transmission Oil on 24H & 24M Motor Graders Equipped with Ecology Drain Valve". Attach particle a count printout and record test results:____________.

22.		After 8 hours of operation without bypassing the filter, inspect the torque converter clean-up filter and install a new standard filter. After 8 hours of operation, check component and related systems for leaks. After one running shift and within 24 clock hours of installation, take a torque converter system oil sample and send to the Cat dealer, with this checklist, completed and signed. At 250 operating hours, perform valve lash check/adjustment At 4,000 operating hours, perform tests in step 20 and report the results to the Cat dealer.						Filter part number:





Technician Name:				Signature:					Date: