Caterpillar Track Type Tractor (D9 - D11) Technician ChecklistTorque Converter (TC) Removal and Installation{0372, 0374, 3101, 3101} Caterpillar

Caterpillar Track Type Tractor (D9 - D11) Technician ChecklistTorque Converter (TC) Removal and Installation{0372, 0374, 3101, 3101}

Usage:

D9H 12U

Track-Type Tractor:: D10 (S/N: 84W1-UP; 76X1-UP); D10N (S/N: 2YD1-UP; 3SK1-UP); D10R (S/N: 3KR1-UP; AKT1-UP); D10T (S/N: RAB1-UP; RJG1-UP; JJW1-UP); D11N (S/N: 4HK1-UP; 74Z1-UP); D11R (S/N: AAF1-UP; 8ZR1-UP; 9TR1-UP; 9XR1-UP; 7PZ1-UP); D11T (S/N: AMA1-UP; GEB1-UP; TPB1-UP; MDG1-UP; JEL1-UP; JNS1-UP); D9 (S/N: 66A1-UP; 91J1-UP; 90V1-UP); D9E (S/N: 50A1-UP); D9G (S/N: 66A1-UP; 90J1-UP; 91J1-UP); D9H (S/N: 12U1-UP; 90V1-UP; 97V1-UP; 98V1-UP; 99V1-UP); D9L (S/N: 14Y1-UP); D9N (S/N: 1JD1-UP; 6XJ1-UP); D9R (S/N: JJB1-UP; HWH1-UP; ABK1-UP; ACL1-UP; 7TL1-UP; 8BL1-UP; WDM1-UP); D9T (S/N: REX1-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	Torque Converter Removed	Torque Converter 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 tractor 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 original shipping containers until installation to keep clean.
	D.	Verify new parts cleanliness. Assure that they are cleaned and capped/ protected against dirt.

3.	Investigate torque converter history or failure cause, if appropriate.
	A.	Question the operator on application, operating conditions, and history. Review SOS history.
	B.	Review VIDS for detected fault information - record the work order folder.
	C.	Take SOS Sample refer to: Contamination Control Guidelines, SEBF8482, "Obtaining Oil Sample for Analysis". Drain the engine and related power train 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 steering clutch and brake assemblies, transmission, and bevel gear group. Clean the power train oil reservoir and 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 torque converter, before and after removal.

6.	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).

7.	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.

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

9.	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.

10.	Install (2) standard 6 micron "clean-up" filters in the torque converter / transmission systems. Use the clean-up filters for at least 8 hours operation time.							Filter part number: __________

11.	Inspect torque converter/transmission filter bypasses and bypass indicators for correct operation.

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

13.	Install new or rebuilt power train oil coolers and oil pump.

14.	If removing transmission, bevel gears, and steering clutches/brakes, thoroughly clean all frame housing mounting surfaces and cavities with a high pressure/temperature wash. Use lint-free towels to clean and check cleanliness. Immediately cover openings to keep clean.
	Supervisor sign-off required.

15.	Clean/protect engine torque converter mounting surfaces and exposed flywheel cavity. Clean/protect replacement component mounting surfaces and exposed cavities.

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/pump drive shafts. Existing bolts cannot be reused.

	Bolt Torque			Specification			Actual
	Main Shaft U-joint
	Pump Shaft U-joint

18.	Reseal cab floor plates, to minimize dust entry.

19.	Install bottom guard.

	Bolt Torque			Specification			Actual
	Bottom Guard Torque

20.	Fill power train system with oil meeting ISO --/16/13 cleanliness level.

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

			Engine				Torque Converter
			Low Idle Speed	High Idle Speed	Stall Speed	Stall Boost	Outlet Pressure
	Specification
	Test

22.	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, SEBF8465, "Procedure for Filtering Transmission Oil in D6-D11 Track-Type Tractor ". Attach particle a count printout and record test results:____________.

23.	After 8 hours of operation without bypassing filters, inspect the power train clean-up filters and install new standard filters (2).							New filter part number: __________
	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 power train system oil sample and send to the Cat dealer, with this checklist, completed and signed. At 4,000 operating hours, perform tests in Step 21 and report the results to the Cat dealer.




Technician Name:			Signature:					Date: