Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797) Technician Checklist Final Drive Removal and Installation {0372, 0374, 4001, 4001, 4011, 4011, 4050, 4050} Caterpillar

Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797) Technician Checklist Final Drive Removal and Installation {0372, 0374, 4001, 4001, 4011, 4011, 4050, 4050}

Usage:

793B 1HL

OEM:: CAT WDS (S/N: M6J1-UP)
Off-Highway Truck/Tractor:: 777 (S/N: 84A1-UP); 777B (S/N: 4YC1-UP); 777C (S/N: 4XJ1-UP); 777D (S/N: AGC1-UP; FKR1-UP; 3PR1-UP; 2YW1-UP; AGY1-UP); 777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP); 777G (S/N: T5A1-UP; TNM1-UP; RDR1-UP; T4Y1-UP); 785 (S/N: 8GB1-UP); 785B (S/N: 6HK1-UP); 785C (S/N: 1HW1-UP; APX1-UP; 5AZ1-UP); 785D (S/N: DMC1-UP; MSY1-UP); 789 (S/N: 9ZC1-UP); 789B (S/N: 7EK1-UP); 789C (S/N: 2BW1-UP); 789D (S/N: SPD1-UP; SHH1-UP); 793 (S/N: 3SJ1-UP); 793B (S/N: 1HL1-UP); 793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP); 793D (S/N: FDB1-UP); 793F Series AC (S/N: EMD1-UP); 793F (S/N: SND1-UP; SSP1-UP; RBT1-UP); 797 (S/N: 5YW1-UP); 797B (S/N: JSM1-UP); 797F (S/N: LAJ1-UP; WSP1-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
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 truck 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 that they are cleaned and capped/ protected against dirt.

3.	Investigate wheel history or failure cause, if appropriate.
	A.	Question the operator on application, operating conditions, and history. Review SOS history.
	B.	Review VIMS, EPTC2, or ET 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 rear axle oil reservoirs and visually check oil for water or debris contaminants. Save any debris.
	D.	Inspect the magnetic drain plugs. Save any debris.
	E.	Remove/inspect system filters/screens and save any contamination evidence.

4.	If a final drive failed generating metal/debris, remove, clean, and inspect/repair both final drives 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.	Inspect the traction aid sensor group for reusability.

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 axle shaft splines, traction aid gear, axle thrust wear surface, and final drive hubcap thrust plate for damage and excessive wear.

9.	Inspect spindle mounting area and machine frame for wear, stripped threads, cracks, or deformation. Repair/replace and paint as needed.

10.	Remove and clean rear axle filtration system, if equipped.

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 the rear axle filter bypass and bypass indicator for correct operation.

13.	Install 6-micron (for dealer rebuilt wheels), or 40-micron (for new/REMAN wheels) clean-up filters in the rear axle lubrication circuit. Use these filters for at least 8 hours of operation time.					Differential Filter Number:
13.						Wheel Station Filter Number:

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

15.	Rebuild/replace brake slack adjuster for the installed final drive axle.

16.	Thoroughly clean mounting surface on axle housing.

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

18.	Inspect/replace electrical connectors and harnesses for loose pins, brittleness, and fatigue.

19.	Clean/protect all mounting surfaces and exposed cavities of the replacement final drives(s).

20.	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.

21.	Fill both final drives and axle housing with oil meeting ISO --/16/13 cleanliness level. Wait 10 minutes and check oil level.

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

		Parking Brake System Pressure		Service Brakes and Retarder System Pressure (Rear)	Brake Cooling (Rear)
		Parking Brake System Pressure		Service Brakes and Retarder System Pressure (Rear)	Right Pressure		Left Pressure
	Spec.
	Test
	4000 Hour Check

23.	Perform brake hold test. Test run truck and inspect for leaks..

24.	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, SEBF8438, "Procedure for Filtering Off-Highway Truck Rear Axle Oil". Attach particle count printout and record highest test:____________.

25.	After 8 hours of operation without bypassing filters, inspect torque converter, clean-up filters, and install new standard filters.						New filter part number: __________
	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 both wheel stations and the differential. Send the sample to the Cat dealer with this checklist, completed, and signed. At 4,000 operating hours, perform tests in Step 22 and report the results to the Cat dealer.


Technician Name:			Signature:				Date: