Procedure To Clean Track-Type Tractor And Pipelayer Power Train Oil Systems Equipped With Electronic Controls {3030, 3101, 4101, 4130} Caterpillar

Pipelayer

572R (S/N: AAC1-UP; 2HZ1-UP)

572R Series II (S/N: DSC1-UP)

583R (S/N: 2XS1-UP)

583T (S/N: CMX1-UP)

587R (S/N: BXL1-UP)

587T (S/N: FAT1-UP)

PL83 (S/N: CB21-UP; KSD1-UP; DLW1-UP)

PL87 (S/N: TEC1-UP; ZAC1-UP; KKJ1-UP)

Track-Type Tractor

D10R (S/N: 3KR1-UP; AKT1-UP)

D10T (S/N: RJG1-UP)

D10T2 (S/N: RAB1-UP; JJW1-UP)

D11R (S/N: AAF1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP)

D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; MDG1-UP; JEL1-UP; JNS1-UP)

D6R (S/N: 2HM1-UP; 4FM1-UP; 8TM1-UP; 9BM1-UP; 2YN1-UP; 3ZN1-UP; 4HN1-UP; 4MN1-UP; 5LN1-UP; 6JN1-UP; 7KN1-UP; 8LN1-UP; 8XN1-UP; 9MN1-UP; 9PN1-UP; DMP1-UP; 4JR1-UP; 4TR1-UP; 4WR1-UP; 5PR1-UP; 5RR1-UP; 6FR1-UP; 6HR1-UP; 6MR1-UP; 7AR1-UP; 7DR1-UP; 7GR1-UP; 9ZS1-UP; 1RW1-UP)

D6R Series II (S/N: BNC1-UP; CAD1-UP; ADE1-UP; BLE1-UP; BRE1-UP; DAE1-UP; ACJ1-UP; BMJ1-UP; BRJ1-UP; BMK1-UP; BNL1-UP; AEM1-UP; AFM1-UP; AGM1-UP; BPM1-UP; AEP1-UP; BPP1-UP; BPS1-UP; BLT1-UP; FDT1-UP; AAX1-UP; BMY1-UP; BPZ1-UP; BRZ1-UP)

D6R Series III (S/N: GJB1-UP; WCB1-UP; HDC1-UP; RFC1-UP; TBC1-UP; HCD1-UP; HKE1-UP; WRG1-UP; MTJ1-UP; DMK1-UP; JEK1-UP; EXL1-UP; JDL1-UP; DLM1-UP; LFM1-UP; LGP1-UP; DPS1-UP; GMT1-UP; MRT1-UP; EXW1-UP)

D6T (S/N: 2D21-UP; CR31-UP; 2B31-UP; MB51-UP; AK71-UP; MH71-UP; CG81-UP; 7C91-UP; SGA1-UP; JHB1-UP; KSB1-UP; ZEB1-UP; ZJB1-UP; JZC1-UP; SMC1-UP; DTD1-UP; JWD1-UP; LBD1-UP; RAD1-UP; LAE1-UP; STE1-UP; DJG1-UP; WCG1-UP; WFH1-UP; EJJ1-UP; LKJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; JML1-UP; KJL1-UP; MEL1-UP; SKL1-UP; JNM1-UP; TSM1-UP; WLM1-UP; WRN1-UP; K1R1-UP; KMR1-UP; PLR1-UP; WES1-UP; GCT1-UP; HYT1-UP; SGT1-UP; JRW1-UP; RCW1-UP; RLW1-UP; LAY1-UP; NDY1-UP; TMY1-UP; HTZ1-UP; PEZ1-UP; SGZ1-UP)

D7R (S/N: BPK1-UP; BNM1-UP; BRM1-UP; 9HM1-UP; 2EN1-UP; 3DN1-UP; BRP1-UP; 2HR1-UP; 3ZR1-UP; 4SR1-UP; 5MR1-UP; 6ER1-UP; BPT1-UP; BNX1-UP; 5KZ1-UP)

D7R Series II (S/N: AEC1-UP; AFG1-UP; ABJ1-UP; AGN1-UP; ACS1-UP; ADW1-UP)

D8R (S/N: JR81-UP; DWJ1-UP; MEJ1-UP; RJM1-UP; 7XM1-UP; 9EM1-UP; T5X1-UP; 6YZ1-UP)

D8R Series II (S/N: AKA1-UP; 6YZ1-UP)

D8T (S/N: AW41-UP; JJ51-UP; MB81-UP; J8B1-UP; FMC1-UP; MLN1-UP; FCT1-UP; KPZ1-UP)

D9R (S/N: ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP)

D9T (S/N: TWG1-UP; RJS1-UP; REX1-UP)

Introduction

This special instruction contains the procedure for cleaning the power train oil system in the above machines. Use this procedure when the power train oil system has been contaminated with a foreign material. This document contains details for machines with electronically controlled transmissions that are not in Special Instruction, SEHS8419. Use both of these documents for machines with electronically controlled transmissions. The following examples are of electronically controlled transmissions:

• electronic long range transmission (ELRT)

• electronic clutch pressure control (ECPC)

• clutch control valves (CCV)

The following components use the same oil reservoir. Failure in one of the components will cause contamination to enter the rest of the components:

• The transmission

• The torque converter

• The steering clutch and brakes or the differential steer unit

• The bevel gear

• The transfer gears

Follow the procedure that is contained in this publication after all causes for the contamination have been identified and corrected.

Reference: Refer to the Disassembly and Assembly for the removal, the disassembly, the assembly, and the installation of the power train components for your machine.

Note: Before removing any component, use "Inspection Procedure" to determine the extent of the power train system that needs cleaning.

Reference: Refer to Special Instruction, REHS8570, Procedure to Clean Power Train System for Certain D7E Track-Type Tractors.

Inspection Procedure

Note: Inspect the components and clean the components in the sequence that is listed starting with the source of the first failure. If debris is found in a particular component, proceed to the remaining components. If debris is not found, it is not necessary to inspect the remaining components.

Note: Not all the affected machines have all the components that are listed in the following inspection sequences and that not all the machines have electronically controlled transmissions.

Steering Clutch and Brake Failure

1. All suction screens

2. All power train oil filters (replace)

3. The oil sump (tank)

4. Priority valve

5. Steering clutch and brake control valve

6. Transmission control valve

7. Transmission modulating valves (ECPC , CCV, or ELRT)

8. Circuit for the flywheel lubrication (including orifices)

9. Torque converter

10. Torque converter outlet relief valve

11. Power train oil cooler

12. Lubrication circuit (including the manifold and the orifices)

13. Power train oil pump

    Note: The power train oil pump can often handle soft debris that passes through the pump. This is the reason that the power train oil pump is being listed last.

Differential Steer and Brake Failure

1. All suction screens

2. All power train oil filters (replace)

3. The oil sump (tank)

4. Priority valve

5. Brake valve

6. Transmission control valve

7. Transmission modulating valves (ECPC , CCV, or ELRT)

8. Circuit for the flywheel lubrication (including orifices)

9. Torque converter

10. Torque converter outlet relief valve

11. Power train oil cooler

12. Lubrication circuit (including the manifold and the orifices)

13. Power train oil pump

    Note: The power train oil pump can often handle soft debris that passes through the pump. This is the reason that the power train oil pump is being listed last.

Transmission and Torque Converter Failure

1. All suction screens

2. All power train oil filters (replace)

3. The oil sump (tank)

4. Transmission control valve

5. Transmission modulating valves (ECPC , CCV, or ELRT)

6. Priority valve

7. Steering clutch and brake control valve or brake valve

8. Circuit for the flywheel lubrication (including orifices)

9. Torque converter

10. Torque converter outlet relief valve

11. Power train oil cooler

12. Lubrication circuit (including the manifold and the orifices)

13. Power train oil pump

    Note: The power train oil pump can often handle soft debris that passes through the pump. This is the reason that the power train oil pump is being listed last.

Failure Of The Power Train Oil Pump

1. All suction screens

2. All power train oil filters (replace)

3. The oil sump (tank)

4. Priority valve

5. Steering clutch and brake control valve or brake valve

6. Transmission control valve

7. Transmission modulating valves(ECPC , CCV, or ELRT)

8. Circuit for the flywheel lubrication (including orifices)

9. Torque converter

10. Torque converter outlet relief valve

11. Power train oil cooler

12. Lubrication circuit (including the manifold and the orifices)

Inspection and Cleaning Procedure

Note: The following guidelines are for the complete power train oil system. All the filters that are referred to in this procedure are pressure filters. This procedure should only be conducted if the power train oil filter bypass has been logged or confirmed. Most of the steps refer to the disassembly, the cleanout, and the reassembly of components. If the components are damaged beyond repair, replacement is required.

1. Drain the oil from the reservoirs for the power train oil. The following is a list of examples of reservoirs for the power train oil:

   • The sump or tank

   • The bevel gear case

   • The transmission

   • The torque converter

2. Remove all screens from the main case, the torque converter, and the transmission. Clean the screens and protect the screens. Then place the screens to the side.

3. Remove the failed component and all other components of the power train oil system that have been identified for removal via the "Inspection Procedure" above.

4. Drain the power train oil filters. Remove the contaminated filter element or elements and discard the contaminated filter element or elements. Remove the filter base or bases from the machine. Disassemble the base or bases and clean the internal components.

5. Assemble the base or bases. Ensure that all passages are clean, and that all spools and poppets are free to move. Put a protective covering on the filter base or bases and place the filter base or bases aside.

6. Remove all hose assemblies and tube assemblies for the power train oil system (excluding the case tubes). Clean these parts with solvent and allow the parts to air dry. Plug both ends of these pieces and place the pieces aside.

7. Use a solvent to flush the power train oil tank (sump) and the tubes that are permanently assembled in the case. Permit these parts to air dry.

8. Remove the torque converter outlet relief valve from the torque converter.

9. Remove the priority valve (PV) and the transmission control valve.

10. Remove the ECPC , CCV, or ELRT valves on the transmission control valve.

11. Disassemble the valve assemblies and clean the valve assemblies (excluding the ELRT, ECPC, and PV modulating valves which will be used for the initial oil filtration), including the valve for the steering clutch and brake control. Clean the small screens that are located within the steering clutch and brake valve.

    Note: CCV valves are not designed for disassembly.

12. Assemble the parts, including reinstallation of the original ELRT, ECPC, and PV valve. Make sure that all passages are clean and that all spools and all poppets are free to move. Put a protective covering on the valves and place the valves aside.

13. Disassemble the steering clutch and brake valve or the brake valve and clean the steering clutch and brake valve or the brake valve. Make sure that all passages are clean.

14. Assemble the steering clutch and brake valves, including reinstallation of the original ELRT or ECPC valves. The valves will be used for the initial oil filtration.

15. Disassemble the power train oil pump and clean the power train oil pump. Assemble the pump after the cleaning procedure is completed.

16. Remove the power train oil cooler. If failure generated metallic debris or dirt (silica) has entered the system, install a new power train oil cooler. If failure generated nonmetallic debris (friction material), then flush the inlet side of the cooler with solvent. Drain the cooler and allow the cooler to air dry. Install the power train oil cooler.

17. Flush the sump areas of the transmission, main case, and torque converter with solvent. Drain and allow time to air dry.

18. Install all components onto the machine.

19. Install a new 6 micron high efficiency power train oil filter or filters.

20. Install a supplemental oil filtration system to the machine.

21. Add clean oil to the sump for the power train oil to the FULL MARK on the "cold oil" or the "engine stopped" side of the dipstick.

    Reference: Refer to the Operation and Maintenance Manual for your machine for the proper procedure and capacity.

22. Start the engine and run the engine at LOW IDLE speed. Do not run the engine at HIGH IDLE speed because of the possibility of opening the filter bypass valve.

23. Check the oil in the sump and add oil to the sump, as needed. The oil level should be at the FULL MARK on the "Warm Oil" or the "Engine Running" side of the dipstick.

24. Continue to run the machine and filter the oil for the machine at LOW IDLE until an ISO level of 16/13 is attained.

25. After filtering the oil, install all new 6 micron filter elements and clean all the screens again.

26. Replace all ECPC , CCV, or ELRT valves.

27. Replace all steering clutch and brake solenoid valves.

28. Download the power train prognostics. This is only available for all the T-Series Track-Type Tractors.

    Reference: Refer to Special Instruction, REHS4335, "Download Procedures For The ECM" for the correct procedure for downloading the power train prognostics.

29. Calibrate the transmission, steering, and brakes.

30. Document all the pressures for the power train oil system.

    Reference: Refer to the Testing and Adjusting manual for your machine for the correct pressures for the power train oil system.

31. Take an S·O·S sample for the baseline.

32. Repeat Step 25 after 4 to 5 hours of operation.

33. If no foreign material is found in the filters and/or screens, and there are not operational problems, install new power train oil filters.

34. After the standard filter elements are installed, return to using the service intervals that are given in your machines Operation and Maintenance Manual.

35. If any foreign material is found in the system, find the cause of the contamination and do additional cleaning, as needed. Check the screens and check the filters at the shorter intervals that are given above.