Caterpillar Wheel Loader and Wheel Dozer (834 - 854, 992 - 994) Technician Checklist Final Drive (FD) and Service Brake, Removal and Installation {0372, 0374, 4001, 4001, 4011, 4011, 4050, 4050, 4251, 4251} Caterpillar

Caterpillar Wheel Loader and Wheel Dozer (834 - 854, 992 - 994) Technician Checklist Final Drive (FD) and Service Brake, Removal and Installation {0372, 0374, 4001, 4001, 4011, 4011, 4050, 4050, 4251, 4251}

Usage:

834U 14B

Wheel Dozer: 834 (S/N: 43E1-UP); 834B (S/N: 7BR1-UP; 92Z1-UP); 834G (S/N: BPC1-UP; 6GZ1-UP); 834H (S/N: BTX1-UP); 834S (S/N: 36G1-UP; 96G1-UP); 834U (S/N: 14B1-UP); 844 (S/N: BBN1-UP; 2KZ1-UP); 844H (S/N: BTW1-UP); 854G (S/N: AMP1-UP; A4W1-UP; 1JW1-UP); 854K (S/N: 2211-UP; KK61-UP; RM61-UP; H9K1-UP; H8M1-UP)
Wheel Loader: 992 (S/N: 25K1-UP); 992B (S/N: 25K1-UP); 992C (S/N: 42X1-UP; 49Z1-UP); 992D (S/N: 7MJ1-UP); 992G (S/N: 7HR1-UP; ADZ1-UP); 992K (S/N: 8801-UP; KK41-UP; RM51-UP; H4C1-UP; ZMX1-UP); 993K (S/N: LWA1-UP; Z4D1-UP; Z8D1-UP; Z9K1-UP; Z4Z1-UP; Z8Z1-UP); 994 (S/N: 9YF1-UP); 994D (S/N: 3TZ1-UP); 994F (S/N: 4421-UP); 994H (S/N: DWC1-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	LH Final Drive Removed	LH Final Drive Installed	RH Final Drive Removed	RH Final Drive Installed
Front Axle Serial Number
Front Axle CID Numbers⁽¹⁾
Rear Axle Serial Number
Rear Axle CID Numbers
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.	A. High-pressure wash the related axle half of the wheel loader to remove all dirt/debris.
	B.	Keep the work area clean and the floor dry – 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 final drive history or failure cause, if appropriate.
	A.	Question the operator on application, operating conditions, and history. Review SOS history.
	B.	Download/review VIDS/VIMS fault information. Record in work order folder and reset VIMS.
	C.	Inspect brake cooling oil tank level (994 only). Take SOS Sample refer to: Contamination Control Guidelines , SEBF8482, "Obtaining Oil Sample for Analysis".
	D.	Take axle SOS samples (3). Drain the axle and brake compartment oil (994 only). Visually check oil for water, coolant, or debris contaminants.
	E.	Inspect the magnetic drain plugs. Save any debris.
	E.	Remove/inspect axle/brake cooling system filters/screens and save any contamination.

4.	If a final drive failed generating metal/debris, remove, clean, and inspect/repair both axle final drives, service brakes, and differential. Use the Caterpillar R & I checklists as needed.

5.	If the repair on the removed final drive will not include a brake repair/rebuild, perform a brake hold test before removal.
		Pass:		Fail:	(check one)

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 axle shaft splines, axle thrust wear surface, and final drive hubcap thrust plate for damage and excessive wear. 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 spindle mounting area, trunnion supports, and machine frame for wear, stripped threads, cracks, or deformation. Repair/replace and paint as needed.

9.	Clean the axle/brake cooling system(s).

10.	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.

11.	Clean or replace all brake lines to maintain systems. Use new seals, hoses & clamps.

12.	Rebuild/replace brake slack adjuster for the installed final drive axle, if equipped.

13.	Inspect/replace electrical connectors and harnesses for loose pins, brittleness, and fatigue. Inspect the axle temperature sensor and indicator for correct operation.

14.	Install axle/brake cooling oil pump(s) if equipped.

15.	Clean/protect the mounting surface(s) on the axle housing.

16.	Clean/protect all mounting surfaces and exposed cavities of the replacement final drives.

17.	Purge brake lines and brakes of any air.

18.	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.

19.	Fill final drives, axle housing, and brake oil cooler tank (if equipped) with oil meeting ISO --/16/13 cleanliness level. Operate machine 10 minutes to purge air in axle/brake cooling system. Shut machine off for 10 minutes and check oil levels. Add oil if needed.

20.	Check brake system pressures. Refer to procedures detailed in the Testing and Adjusting manuals.

			Specification	Test	4000 Hr Check
	Service Braking System Pressure

21.	Perform brake hold test. Test run wheel loader and inspect for leaks.

22.	Before releasing machine, test each (3) related axle compartment's oil for cleanliness. Kidney-loop filtration may be required to achieve ISO cleanliness level of --/18/15 refer to Contamination Control Guidelines , SEBF8445, "Procedure for Filtering Off-Highway Truck (769-793) Transmission Oil". Attach particle a count printout and record test results:____________.

23.	After 8 hours of operation, inspect the magnetic plug and check component and related systems for leaks. After one running shift and within 24 clock hours of installation, take an SOS sample from the repaired axle's final drives, the differential, and the brake cooling oil tank (if equipped). Send to the Cat dealer, with this checklist, completed and signed. At 4,000 operating hours, perform tests in Step 19 and report the results to the Cat dealer.

Technician Name:			Signature:			Date: