5031270 JOHNSON *SEAL, OIL

Table 1
Customer Name/ Location     Machine Unit Number     Machine Serial Number     Machine Service Meter Hours     Work Order Number    
/                    
Table 2
Tracking Data     Engine Removed     Engine Installed     T/C Removed     T/C Installed    
Serial Number                    
CID Number (1)                    
Source/Rebuilder (2)                    
( 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
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 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 and EPTC2 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.         Clean engine compartment with high-pressure wash before and after engine 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 engine mounts and machine frame for stripped threads, cracks, or deformation. Repair/replace and paint as needed.    
   
7.         Inspect and clean or replace system hoses/tubes. Clean with Cat hose cleaner group. Refer to Reuse and Salvage Guidelines, NEHS0643 and Reuse and Salvage Guidelines, SEBF8485. Use new clamps (torque to spec), O-ring seals, and gaskets.    
   
8.         Inspect/replace electrical connectors and harnesses for loose pins, brittleness, and fatigue. Replace the engine wire harness every rebuild life cycle.    
   
9.         Install cleaned/repaired or new radiator cores. Perform hydraulic fan drive system calibration.    
   
10.         Clean/protect pump drive mounting surfaces and exposed cavities of the replacement components.    
   
11.         Install rebuilt/new pump drive coupling.    
   
12.         Clean/protect all mounting surfaces and exposed cavities of the replacement components.    
   
13.         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.    
   
14.         Clean/replace the primary air filters. Replace the secondary air filters. Clean the pre-cleaners. Reset air filter restriction indicator. Insure air induction system integrity (before turbocharger).    
   
15.         Prelube the engine with oil meeting ISO --/16/13 cleanliness level and prime the fuel system before starting.    
   
16.         Check engine s