CATERPILLAR

TRACK TYPE TRACTOR (D9-D11) TECHNICIAN CHECKLIST

ENGINE & TORQUE DIVIDER (TD) REMOVAL AND INSTALLATION

These checks are required for component removal & installation. Initial each check after completion.
Note: Service literature procedures, specific to the model & serial number, must be used in this
process. The checklist does not substitute procedures for those given in the service literature.

Customer Name / Location Machine Unit # Machine Serial # Mach Svc Mtr Hrs Work Order #
/
Tracking Data Engine Removed Engine Installed T/D Removed T/D Installed
Serial #
CID #
Source/Rebuilder
Note: CID (Component Identification) is the number assigned to the component by the user/dealer.
Note: Source/Rebuilder is either NEW, REMAN, DLR (Dealer Rebuilt), or CUST (Customer Rebuilt).

01. Record Complaint:

02. Pre-repair contamination control.

A. High-pressure wash the tractor to remove all dirt/debris.

B. Maintain a well-organized work area and plan to contain all fluid spills.
C. Keep components in original shipping package until installation, to keep clean.
D. Verify new parts cleanliness. Assure they are cleaned & capped/protected against dirt.

03. Investigate engine and torque divider history or failure cause, if appropriate.

A. Question the operator on application, operating conditions, and history. Review SOS history.
B. Review VIDS for detected fault information – record in work order folder.
C. Take SOS sample (reference SEBF8482). Drain the engine and 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.

04. If the torque divider failed generating metal/debris, remove, clean, and inspect/repair the
steering clutch and brake assemblies, transmission, and bevel gear group. Clean the power
train oil reservoir and all vulnerable oil system screens/components (reference the System
Operations manual). Use the Caterpillar R&I checklists as needed.

05. High-pressure wash the machine area around the engine and TD, before and after removal.

06. Cover and cap all cleaned and reused components until installed to prevent dirt entry.
Cover all removed component cores with plastic sheets until shipping covers are available.

07. Inspect drive shaft splines and U-joints for wear/damage. Reference SEBF8126, Guidelines for
Reusable Parts, Universal Joints & Drive Shafts. Spline tooth wear limit is 0.2 mm (0.008 inch).

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

09. Inspect and clean or replace system hoses/tubes. Clean with CAT hose cleaner group
(reference NEHS0643 and SEBF8485). Use new clamps (torque to spec), o-ring seals, and
gaskets.
Caterpillar Form No. 01-040524-00 (PC) Page 1 of 2 (07/01/2003)
not available for order
 10. Install standard 6-micron filters (2) in the TD/transmission systems. Use as
clean-up filters for at least 8 hours operation time. Record filter Part #:

11. Inspect torque divider/transmission filter bypasses and bypass indicators for correct operation.
Inspect/replace electrical connectors and harnesses for loose pins, brittleness, and fatigue.
Replace the engine/torque divider wire harness every rebuild life cycle.

12. Install new or rebuilt power train oil coolers and oil pump.

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

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

15. Transfer all covers/plugs to the removed component cores and pack into shipping containers to
prevent damage and dirt entry. Tag with completed Caterpillar dealer core tag.

16. Clean/replace the primary air filters. Replace secondary air filters. Clean pre-cleaners. Reset
air filter restriction indicator. Insure air induction system integrity (before turbocharger). Fill
power train with oil meeting ISO --/16/13 cleanliness level.

17. 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

18. Reseal cab floor plates, to minimize dust entry.

19. Install bottom guard.

Bolt Torque Specification Actual
Bottom Guard Torque

20. Prelube engine (with ISO --/16/13 cleanliness level oil) and prime the fuel system before starting.

21. Check engine and torque divider speeds and pressures. Refer to procedures detailed in the
Testing and Adjusting manuals.
Engine Torque Divider
Low Idle High Idle Stall Stall Outlet
Speed Speed Speed Boost Pressure
Specification
Test

22. Before releasing machine, test the TD system oil for cleanliness. Kidney-loop
filtration may be required to achieve ISO cleanliness level -- /18/15
(reference SEBF8445). Attach particle count printout & record test results: -- / /

23. x After 8 hours of operation without bypassing the filters, inspect the power train
clean-up filters and install new standard filters (2). New filter part #:
x After 8 hours of operation, check component and related systems for leaks.
x After one running shift and within 24 clock hours of installation, take a power train system oil
sample and send to the Caterpillar dealer, with this checklist, completed and signed.
x At 250 operating hours, perform valve lash check/adjustment
x At 4,000 operating hours, perform tests in step 21 and report the results to the CAT Dealer.

Technician Name: Signature: Date: / /

Caterpillar Form No. 01-040524-00 (PC) Page 2 of 2 (07/01/2003)
not available for order