Caterpillar Wheel Loader and Wheel Dozer (834 - 854, 992 - 994) Technician Checklist Engine and Torque Converter (TC) Removal and Installation {0372, 0374, 1000, 1000, 1003, 1003, 3101, 3101} Caterpillar

Caterpillar Wheel Loader and Wheel Dozer (834 - 854, 992 - 994) Technician Checklist Engine and Torque Converter (TC) Removal and Installation {0372, 0374, 1000, 1000, 1003, 1003, 3101, 3101}

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	Engine Removed	Engine Installed	T/C Removed	T/C 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 wheel loader to remove all dirt/debris.
		B.	Keep the work area clean and the floor dry – contain all fluid spills.
		C.	Keep components covered until installation. Assured new parts are protected against dirt.

3.		Investigate engine and torque converter 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.	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 transmission and transfer gears. Clean 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 engine and torque converter, before and after removal.

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 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).

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

9.		Inspect TC/transmission filter bypasses & bypass indicators for correct operation.

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

12.		Install 6-micron "clean-up" filters in the TC system (also implement hydraulic and steering filters if systems were opened for pump removal). Use the clean-up filters for at least 8 hours operation time.						TC filter part # :
								Hydraulic filter part # :
								Steering filter part # :

13.		Install new or rebuilt torque converter oil cooler, and oil pump.

14.		Install cleaned/repaired or new radiator cores. Install a rebuilt/new fan drive or check fan drive hydraulic pump and motor systems (see step 20).

15.		Install cleaned/repaired or new radiator cores. Perform hydraulic fan drive system calibration.

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

17.		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.

18.		Use new bolts/u-joints to install the drive shafts. Existing bolts cannot be reused. Torque bolts twice. Refer to Service Magazine, SEPD0572, "Correction to the Torque Procedure for the Drive Shaft Bolts ".

		Bolt Torque			Specification			Actual
		Main Shaft U-joint

1.		Clean/replace the primary air filters. Replace secondary air filters. Clean the pre-cleaners. Reset air filter restriction indicator. Insure air induction system integrity (before turbocharger).

20.		Prelube engine and fill torque converter system with oil meeting ISO --/16/13 cleanliness level. Prime the fuel system before starting.

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

		Engine Speed				Torque Converter		Transmission		Fan
		Low Idle	High Idle	Single Stall	Double Stall	Outlet Relief Pressure	Impeller Clutch Max. Pressure	Pump Pressure	Lube Pressure	High Pressure Cut Off Pressure
	Spec.
	Test
	4000 Hr Check

22.		Before releasing machine, test TC, hydraulic and steering system (if opened) oil. Kidney-loop filtration may be required to achieve ISO cleanliness level of --/18/15 (reference SEBF8452, SEBF8458, and SEBF8494). Attach particle count printout.						TC results:
								Steering results :
								Hydraulic results:

23.		After 8 hours of operation without bypassing filters, inspect the torque converter, steering, and hydraulic clean-up filters and install new standard filters. 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 250 operating hours, perform valve lash check/adjustment. At 4,000 operating hours, perform tests in Step 21 and report the results to the Cat dealer.						TC filter part # :
								Hydraulic filter part # :
								Steering filter part # :


Technician Name:				Signature:					Date: