Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797) Torque Converter Removal and Installation Technician Checklist {0372, 0374, 3101, 3101} Caterpillar

Caterpillar Off-Highway Truck (777, 785, 789, 793, and 797) Torque Converter Removal and Installation Technician Checklist {0372, 0374, 3101, 3101}

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	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 truck to remove all dirt/debris.
		B.	Clean the rear half of the truck with a high-pressure wash to remove all dirt debris.
		C.	Keep the work area clean and the floor dry - contain all fluid spills.
		D.	Cover components with plastic or keep in containers until installation to keep clean.
		E.	Verify new parts cleanliness. Assure that they are cleaned and capped/ 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.	Review VIMS, EPTC2, and/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 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.		High-pressure wash the machine area around the torque converter, before and after removal.

5.		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.

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

8.		Open, clean, and inspect torque converter oil reservoir.

9.		Inspect the transmission and torque converter filter bypass and bypass indicator for correct operation.

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

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.		If the torque converter failed generating metal debris, then remove, disassemble, and clean all vulnerable screens/components in the oil system (refer to the System Operations Manual).

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

14.		Install new or rebuilt torque convertor, oil cooler, and oil pump.

15.		Clean and protect engine torque converter mounting surfaces and exposed flywheel cavity.

16.		Clean and protect all mounting surfaces and exposed cavities of the replacement torque converter.

17.		Transfer all covers and 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 main/pump drive shafts. Existing bolts cannot be reused.

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

19.		Check engine, torque converter, and transmission speeds and pressures. Refer to procedures detailed in the Testing and Adjusting manuals.
		For Off-Highway Truck (769-793) record the following:

		Engine Speed			Torque Converter			Transmission
		Low Idle	High Idle	Stall	Outlet Relief Pressure	Parking Brake Release Pressure	Lock-up Clutch Max. Pressure	Pump Pressure	Lube Pressure	Dual Stage Relief Valve Pressure
	Spec.
	Test
	4000 Hour Check

		For Off-Highway Truck (797) record the following:
		Engine Speed		Torque Converter			Transmission
		Low Idle	High Idle	Outlet Relief Press.	Parking Brake Release Press.	Lock-up Clutch Max. Press.	Charge Press.	Latching Press.	Main Lube Press.	Front and Rear Clutch Lube Press.
	Spec.
	Test
	4000 Hour Check


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

21.		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, SEBF8445, "Procedure for Filtering Off-Highway Truck (769-793) Transmission Oil" or Contamination Control Guidelines, SEBF8460, "Filtration Procedure for Off-Highway Truck Transmission and Torque Converter Oil". Attach particle a count printout and record test results:____________.

22.		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, 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. Send the sample 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: