- Track-Type Tractor
- 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)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This special instruction contains the procedure for cleaning the fan/implement oil system in the above machines. Use this procedure when the fan and/or implement oil systems have been contaminated with a foreign material.
The following components are directly connected to the same oil reservoir. Failure in any one of the directly connected and/or indirectly connected components can cause contamination to enter the rest of the components via inlets and drains to/from the components:
| Machine Configuration | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| Part Number | Description | AAF | 7PZ | 9TR | 9XR | GEB | TPB | JEL | AMA | JNS | MDG |
| 157-4761 | Gear Pump Gp - IMPL - 241 CC/REV & 81 CC/REV | X | |||||||||
| 445-2672 | Gear Pump Gp - IMPL - 429 LPM 144 LPM AT 1980 RPM & DOZER RELIEF PRESSURE | X | X | X | X | ||||||
| 228-4838 | Gear Pump Gp - IMPL 373 LPM & 231 LPM AT 1900 RPM & DOZER RELIEF PRESSURE | X | X | X | X | ||||||
| 6E-5294 | Gear Pump Gp GEAR 456 & 154 LPM FLOW AT 1890 RPM | X | |||||||||
| 124-6990 | DOZER Control Valve Gp DOZER LIFT & TILT | X | |||||||||
| 127-1604 | Control Valve Gp 5-45(A) - DOZER 50-250 PSI - LIFT, RT, LT -300 PSI FLOAT | X | |||||||||
| 204-5575 | Control Valve Gp 5-45(A) - DOZER 50-250 PSI - LIFT, RT, LT -300 PSI FLOAT | X | |||||||||
| 209-3687 | Control Valve Gp 5-45(A) - DOZER 50-250 PSI - LIFT, RT, LT -300 PSI FLOAT | X | |||||||||
| 244-5438 | Control Valve Gp 5-38(A) - DOZER LIFT & TILT | X | X | X | |||||||
| 244-5440 | Control Valve Gp 5-3 DOZER LIFT & TILT | X | X | X | |||||||
| 106-9648 | Tilt Control Valve Gp DOZER DUAL TILT & TIP | X | |||||||||
| 132-5077 | Shuttle Valve Gp RESOLVE - ENGINE OFF LOWER SIGNAL | X | |||||||||
| 145-6054 | Pilot Valve Gp PILOT - 2 FUNCTION - DOZER LIFT & TILT - ELEC/HYD | X | |||||||||
| 147-1223 | Solenoid Valve Gp - 24 VDC SENDS PILOT to RV PORT - 7T-9745 MANIFOLD | X | X | ||||||||
| 152-8340 | Solenoid Valve Gp - 24 VDC SENDS PILOT to RV PORT - 7T-9745 MANIFOLD | X | X | X | |||||||
| 173-3204 | Pilot Valve Gp PILOT - 4 FUNCTION = DOZER LIFT, TILT, & RIPPER LIFT, TIP | X | X | ||||||||
| 225-2321 | Tilt Control Valve Gp DUAL TILT DEFAULT = DUAL TILT, S1 = PITCH, S2 = SINGLE TIILT | X | |||||||||
| 285-5625 | Main Control Valve and Mounting Gp E/H PILOT VALVE; DOZER LIFT & TILT, RIPPER RV | X | X | X | X | X | X | ||||
| 9T-7884 | Bank Valve DOZER TILT, RIPPER LIFT & TILT | X | |||||||||
| 162-5239 | Manifold MACHINE OFF IMPLEMENT LOWER | X | X | X | |||||||
| 232-3242 | Control Manifold Gp - RELIEF - PILOT SUPPLY SELECTOR & REDUCER | X | X | X | X | X | X | ||||
| 7T-9745 | Valve Manifold - SOLENOID VALVE - ENGINE RETARDING SYSTEM MANIFOLD | X | |||||||||
| 145-0772 | Piston Pump Gp FRONT PUMP - 71 CC/REV, REAR PUMP - 22 CC/REV | X | X | ||||||||
| 172-5638 | Piston Pump Gp FRONT PUMP 71 CC/REV, REAR PUMP 22 CC/REV | X | X | ||||||||
| 204-2576 | Piston Pump Gp DEMAND FAN PUMP & PILOT SUPPLY | X | X | ||||||||
| 340-2121 | Piston Pump Gp Demand Fan Pump & Pilot Supply | X | X | X | X | ||||||
| 159-7161 | Piston Motor Gp DEMAND FAN DRIVE -125 CC/REV | X | X | ||||||||
| 323-3618 | Piston Motor Gp DEMAND FAN MOTOR 125 CC/REV (REVERSING FAN 323-3616) | X | X | ||||||||
| 355-2403 | Piston Motor Gp Demand Fan MO - TOR 107 cc/rev (Reversing Fan 355-2404) | X | X | X | X | ||||||
| 6E-3905 | Piston Motor Gp PISTON DEMAND FAN HIGH AMBIENT MOTOR (125 CC/REV) | X | |||||||||
| 105-2470 | Makeup Valve MOTOR ANTI - CAVITATION BYPASS | X | X | X | X | ||||||
| 190-3832 | Oil Cooler Core Gp HYD OIL - WATER OVER OIL | X | X | ||||||||
| 338-1924 | Oil Cooler Core As Hyd Oil - Air Over Oil | X | X | X | X | ||||||
| 7N-9182 | Hydraulic Oil Cooler Gp HYD OIL - WATER OVER OIL | X | X | X | X | ||||||
| 4T-0884 | Bypass Valve Gp COOLER BYPASS | X | X | X | X | X | X | ||||
| 124-8335 | Bypass Valve Gp COOLER BYPASS | X | X | X | X | ||||||
| 136-9411 | Hydraulic Fan Valve and Mounting Gp SOLENOID - DEMAND FAN CONTROL VALVE | X | X | ||||||||
| 149-2610 | Solenoid Valve Gp - ARCTIC OPTION | X | |||||||||
| 189-8627 | Solenoid Valve Gp - DEMAND FAN CONTROL VALVE, 189-8628 VALVE GP | X | |||||||||
| 226-6537 | Control Manifold Gp - FAN PUMP | X | X | X | X | ||||||
| 345-8526 | Manifold - FAN PUMP | X | X | X | X | ||||||
| 229-1466 | Control Manifold Gp - Diverter - REVERSING VALVE FOR FAN ATTACHMENT | X | |||||||||
| 133-1281 | OIL Filter Gp - KIDNEY LOOP FILTER BETA 6 = 75, BYPASS = 345 kpa | X | X | X | |||||||
| 263-3308 | Hydraulic Screen Gp PART OF 266-0290 SCREEN OPTION (DISCHARGE SCREEN OPTION) | X | |||||||||
| 285-0139 | Control Valve Gp - RIPPER - RIPPER LIFT & TIP (RIPPER OPTION) | X | X | X | X | X | X | X | X | ||
| 9T-8213 | Control Valve Gp - RIPPER LIFT & TIP | X | X | ||||||||
| 507-0647 | Check Valve - VACUUM - VACUUM BREAKER 210 kpa SETTING WITH MANUAL VENT | X | X | X | |||||||
| 220-0812 | Breaker Relief Valve - EU COMPLIANT VACUUM BREAKER 35 kpa SETTING WITH MANUAL VENT | X | |||||||||
| 164-4536 | Diverter Valve Gp ( AUTO CARRY OPTION) | X | X | X | X | X | X | X | X | ||
| 227-6744 | . Pressure Switch Gp - EXTERNAL DELTA PRESSURE SWITCH, FAN FILTER BYPASS INDICATOR | X | X | X | X | X | X | ||||
| 258-0883 | Pressure Switch Gp - CASE DRAIN BYPASS INDICATOR (REF SENSORS & SWITCHES) | X | X | X | X | X | X | ||||
Follow the procedure that is contained in this publication after all causes for the contamination have been identified and corrected.
Note: Before removing any component, use the "Inspection Procedure" to determine the extent of the hydraulic system that needs cleaning.
Safety Section
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
| NOTICE |
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Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation. |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
| NOTICE |
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Maintain the oil in the hydraulic system at the correct level to prevent pump cavitation. |
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.
Fan/Pilot System Failure
- All suction/return screens.
- All hydraulic oil filters (replace).
- The oil sump (tank).
- Front/rear pumps.
- Fan motor.
- Hydraulic oil cooler.
- Solenoid valves.
- Anti-cavitation bypass valve (if so equipped).
- Diverter valve (if so equipped).
- Ripper control valve (if so equipped).
- Pressure sensors/switches (if so equipped).
Note: The tandem fan/pilot pump groups are piston pumps that are largely intolerant of debris and contamination. Because of the design of the fan systems on select D11R and D11T dozers, if the front or rear pump fails, it is likely that the subsequent pump should be checked for debris and/or damage.
Implement System Failure
- All suction/return screens.
- All hydraulic oil filters (replace).
- The oil sump (tank).
- Implement pump.
- Dozer control valve (lift/tilt).
- Pilot valve.
- Solenoid valves.
- Manifolds.
Note: Pending the type of failure in the implement system, it may also be necessary to check the lift, tilt, ripper cylinders as well.
Inspection and Cleaning Procedure
Note: The following recommendations are for the complete hydraulic system in the event of a component failure (i.e.- pump, motor, valve, cylinder, or otherwise). All of the filters that are referred to in this procedure are pressure filters. This procedure should only be conducted if the hydraulic 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.
- Drain the oil from the reservoirs for the hydraulic oil. The following is a list of examples of reservoirs for the hydraulic oil:
- The sump or tank
- Implement pump case
- Fan/pilot pump case(s)
- Fan motor case
- Remove all screens from the hydraulic tank. Clean the screens and protect the screens. Then place the screens to the side.
- Remove the failed component and all other components of the hydraulic system that have been identified for removal via the "Inspection Procedure" above.
- Drain the hydraulic 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.
- 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.
- Remove all hose assemblies and tube assemblies for the hydraulic system. Clean these parts with solvent and allow the parts to air dry. Plug both ends of these pieces and place the pieces aside.
- Use a solvent to flush the hydraulic oil tank and any tubes that are permanently assembled in the tank. Permit these parts to air dry.
- If debris/contamination is found in any of the pump/motor case oil, it may be necessary to remove the pump/motor in question and perform a tear-down inspection. Should the inspection reveal severe internal damage (beyond repair of existing components), it will require a complete rebuild or a new/reman unit replacement.
- Pending the level of damage to the pump/motor gps, it may also require the inspection of components downstream (i.e. – implement valve, manifolds, etc.). It will certainly require the inspection of solenoid valves for debris in screens/edge filters and the inspection of valve section spools for damage/debris. Again, pending the level of damage to the internals may require replacement of the component gp or lower-level serviceable part(s).
- Should evidence be found in the implement valve of debris/contamination, it may further require the downstream components to also be inspected (i.e. – cylinders, etc.).
- Install all components, hoses, hard lines, etc. onto the machine.
- Install a new high efficiency hydraulic oil filter or filters.
- Install a supplemental oil filtration system to the machine (i.e. – kidney loop).
- Add clean oil to the hydraulic tank to the FULL MARK on the "cold oil" or the "engine stopped" side of the dipstick. Oil must be at an ISO level of at least 16/13. It is also highly recommended that all pump/motor cases also be filled with oil rather than trying to gravity feed the components from the hydraulic tank
Reference: Refer to the Operation and Maintenance Manual for your machine for the proper procedure and capacity.
- Start the engine and run the engine at LOW IDLE speed. Allow the oil to circulate throughout the hydraulic system and purge air in the components, hoses, etc. Listen for and observe any errant noises throughout the hydraulic system that persist. Until air is purged from the pumps/motors, it is likely that noise levels of these components will be increased.
Note: DO NOT run the engine at HIGH IDLE speed because of the possibility of opening the filter bypass valve.
- Check the oil in the hydraulic tank, and add oil to the tank, as needed. The oil level should be at the FULL MARK on the "Warm Oil" or the "Engine Running" side of the dipstick
- Continue to run the machine and filter the oil for the machine at LOW IDLE until an ISO level of 16/13 is attained.
- After filtering the oil, install all new filter elements, and clean all the screens again.
- Download the prognostics or Product Status Report (PSR). 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 prognostics.
- Pending the failure type, calibration of the system will be necessary.
- Document all the pressures for the subsequent hydraulic system.
Reference: Refer to the Testing and Adjusting manual for your machine for the correct pressures for the power train oil system.
- Take an S·O·S sample for the baseline.
- Repeat Step 22 after 4 to 5 hours of operation, end of shift, or when practical.
- If no foreign material is found in the filters and/or screens, and there are no operational problems, install new oil filters.
- After the standard filter elements are installed, return to using the service intervals that are given in your machines Operation and Maintenance Manual.
- 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.
Reference Section
Refer to the Disassembly and Assembly for the removal, the disassembly, the assembly, and the installation of the hydraulic components for your machine.
Refer to Special Instruction, REHS4331, "Procedure To Clean Track-Type Tractor And Pipelayer Power Train Oil Systems Equipped With Electronic Controls".