PT Trakindo Utama COMPONENT CONDITION REPORT

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SO Number : 8500293911 Reported By : Iput Triraharjo

SO Reference* : Reported Date : 4/27/2024

Checked by Approved by
: :
Foreman / Superior Service Head
Irfan Budi Setiawan
Wardoyo
(Name and Signature) (Name and Signature)
*Previous Service Order/Sales Order
SIMS Information
DEALER EQUIPMENT NUMBER CUSTOMER
CODE J211 BD-01 NAME PT ANSAF INTI RESOURCE
TECHNICIAN EQUIPMENT
DATE 27-Apr-24 IDENTIFICATION 12256 LOCATION SAMBOJA KM.29
CATERPILLAR CATERPILLAR INSTRUCTION T.SHOOT HIGH TRANSMISSION OIL
MODEL D6R SERIAL NO. TTT00450
TEMPERATURE.
HOURS 14024 KILOMETERS

PART NUMBER PART NAME QTY DESC.* GROUP NUMBER GROUP NAME ✓ IF MADE PRODUCT ✓ IF DURABILITY DESCRIPTIVE COMMENTS (20 SPACES
RESPONSIBLE CODE CONTAINING PART INOPERABLE ISSUE MAXIMUM PER INCIDENT)

1 42 3000 TRANSMISSION OVERHEATING

& DRIVE LINE

DESCRIPTION CODES * A – Structural C – Leaks E – System Malfunction G – General Repair K - Serviceability X – Operator
(Refer SIMS Guidelines : B – Surface D – Factory Assembly F – Factory Shipping H – Adjustment N - Abuse Complaint
SEBD0850)

Supporting Documentation Required

# Description Yes Comments
1 Installation Check List ☐
2 Repair & Maintenance History ☐
3 SOS History ☐
4 Magnetic Plug Inspections ☐
5 ET/VIMS Data ☐
6 TPMS / Payload Data ☐
7 Performance Test Data ☐
8 Others ☐
PT Trakindo Utama COMPONENT CONDITION REPORT
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Failure Outline : Brief outline of what the Customer reported

The customer reported that the transmisson oil was overheating & low power after engine GP replacement performed by the customer.

Repair & Maintenance History : State all the previous repair and maintenance history related to the current events

Engine was overhauled by customer & transmission hoses are replaced (not original Caterpillar Parts)

LIST POSSIBLE CAUSES

Make a list of failure’s possible causes
• Power train oil level is low
• The power train oil cooler has leaks
• The power train oil contains a large amount of air
• The temperature gauge is not operating properly.
• The power train oil cooler is plugged.
• The fan motor is not operating properly
• The scavenge screen is obstructed. There is a large amount of oil.

Part Name :
Part No. : Photo / Drawing
Failure Mode :
CUSTOMER REPORT,

CUSTOMER INFORM HIGH TRANSMISSION

OIL TEMPERATURE & NEED TU
TECHNICIAN TO PERFORM INSPECTION

The machine works at the customer site Somboja

KM.29 - Kutai Kartanegara - East Kalimantan
(Near Samator)
PIC,
Mr. Yahya Ansaf Machine Picture
+62 812-4456-1504
PT Trakindo Utama COMPONENT CONDITION REPORT
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Model D6R2 XL (BD-01)

Serial Number TTT00450 Photo / Drawing
SMU 14024 Hrs

Front View RH View

LH View Rear View

PT Trakindo Utama COMPONENT CONDITION REPORT
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Model D6R2 XL (BD-01)

Serial Number TTT00450 Photo / Drawing
SMU 14025 Hrs
21 April 2024 Transmission screen & filter

Tech Name : Dida A – Bambang R

SO : 8500293911

* Safety Induction
* Walk around inspection and interview for history,
engine was overhauled by customer & transmission
hoses are replaced (not original Caterpillar Parts)
* Check XSMN Screen, not found any big particles,
but oil level is too low. Refill XSMN oil ± 100L
* Check Filter XSMN, not found any big particles
* Check TC Inlet & Outlet pressure, XSMN
Lubrication pressure, all values are within
specifications
* Download data, found error at Reverse Selector &
TOS. Found selector has been repaired (added jumper Torque Converter Inlet & Outlet Pressure
cable) but pinched by armrest. Repair as necessary.
* Ground test unit for ± 1 hour, the problem
overheating still occur
* Remove floor, inspect deeply for any abnormal
conditions, found hose XSMN Pump Inlet is Flat
(Vacuum after low oil level). May cause restrictions
for oil supply
• Coordination with customer for repositioning hose. Transmission selector reverse direction switch : Erratic, intermittent, or incorrect

Agreed to perform next day BEFORE AFTER

* Prepare container for drain oil xsmn

Continue,
Waiting info from customer for next test

Transmission selector reverse direction switch (Temporary Repaired)

Hose of Transmission Pump inlet was flat

PT Trakindo Utama COMPONENT CONDITION REPORT
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Model D6R2 XL (BD-01)

Serial Number TTT00450 Photo / Drawing
SMU 14029 Hrs
25 April 2024

Tech Name : Iput T. – Indra S.

SO : 8500293911

- Report to customer & Safety induction.

- Check unit condition & visual inspection.
- Check all fluid level OK.
- Check Lines power train system.
- Performance test & Ground test machine (by
operator) +/- 3 hours found High Transmission oil
temperature.
- Check Xmsn oil level found Low level & inspect
Power train system (Lower) found leaks oil from
gasket Starting motor.
- Info to customer for added Xmsn oil & reposition
machine to workshop from Dumping area.
- Inspection machine & prepare box to check screen
torque converter.

Continue…

Starting Motor
PT Trakindo Utama COMPONENT CONDITION REPORT
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Model D6R2 XL (BD-01)

Serial Number TTT00450 Photo / Drawing
SMU 14031 Hours
26 April 2024
SCREEN T/C
Tech Name : Iput T. – Indra S.
SO : 8500293911

- Report to customer.
- Check unit condition & visual inspection.
- Check xmsn oil found overfill, drain & leveling OK.
- Check Lines power train system found 3T-6471
Tighten Bolts St. Motor
Screen As T/C Scavenge was not installed.
- Found bolt of mounting St.motor was loosen &
tighten the bolts.
- Performance test & Ground test machine (by
operator) +/- 2½ hours found High Transmission oil
temperature.
- Check Xmsn oil level found Low level & leaks oil
out from breather xmsn.
- Info to customer for added Xmsn oil & reposition Power Train Breather
machine to workshop from Dumping area.

Continue
PT Trakindo Utama COMPONENT CONDITION REPORT
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Model D6R2 XL (BD-01)

Serial Number TTT00450 Photo / Drawing
SMU 14033 Hours
27 April 2024 Low Idle 110 Psi High Idle 330 Psi

Tech Name : Iput T. - Aditya P.W

SO : 8500293911

- Report to customer. Transmission Main Relief Valve Pressure

- Check unit condition & visual inspection.
- Cleaning Dirty oil at T/C area & Power train lines.
- Check Xmsn Main relief valve pressure LI/HI found
Low pressure 110/330 Psi (Spec. 380/400 Psi)
- Check T/C Inlet/Outlet Relief valve within
specification.
- Inspect of Power train leaks oil at Lower side found
2ea Hose Transmission 431-4858 Hose As & 426-
2453 Hose As was leaks oil.
- Performance test & Ground test machine (by
operator) +/- 2 hours found High Xmsn oil
temperature, Low power & Leaks oil (Built up oil at
T/C & exits through the st.motor gasket & power train
breather. Indicated 1ea 420-0748 Pump GP Gear
(Transmission & Torque Converter) was Problem.
The Torque Converter scavenges oil from the torque
converter housing & enters the pump through the
pump inlet not optimally (References Power Train
Oil Pump (UENR4109-02))
- Check Xmsn oil level found still level & reposition
to w.shop from Dumping area.
- Check Xmsn Main relief valve pressure (After High
Xmsn Oil temp.) LI/HI found Low pressure 55/255
Psi (Spec. 380/400 Psi)
- Report to customer.

Low Idle 55 Psi High Idle 255 Psi

Transmission Main Relief Valve Pressure (Tested with High Xmsn Oil Temp.)
PT Trakindo Utama COMPONENT CONDITION REPORT
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D6R2 Track-Type Tractor Technical Inspection

Power Train System

Reference:
Refer to Testing & Adjusting, UENR4109, "Power Train System" for more detail on the following test.

Relief Valve (Main) - Test

Status(1) Specification
Description Actual Comments
Flow Rate Pressure Setting
38 ± 4 L/min 21700 ± 400 kPa
Standard - -
(10 ± 1 US gpm) (3147 ± 58 psi)
Standard with a winch 10 ± 2 L/min 29600 ± 500 kPa
- -
VPAT with a winch (3 ± 1 US gpm) (4293 ± 73 psi)
38 ± 4 L/min 24400 ± 400 kPa
VPAT - -
(10 ± 1 US gpm) (3539 ± 58 psi)
(1)
N = Normal, M = Monitor, A = Action
Relief Valve (Transmission) - Test and Adjust
Status(1) Description Specification Actual Comments
Relief Valve Low Idle at pressure tap (P)
A 110 psi Low Pressure
(Transmission) 2610 ± 104 kPa (379 ± 15 psi)
Relief Valve High Idle at pressure tap (P)
A 330 psi Low Pressure
(Transmission) (Tier II) 2800 ± 138 kPa (406 ± 20 psi)
Relief Valve High Idle at pressure tap (P)
- -
(Transmission) (Tier III) 2780 ± 138 kPa (403 ± 20 psi)
(1)
N = Normal, M = Monitor, A = Action
Relief Valve (Torque Converter Inlet) Pressure - Test
Status(1) Description Specification Actual Comments
High Idle with the parking brake
Torque Converter Inlet engaged at pressure tap (M) less
N 110 psi OK
Relief Valve (Tier II) than 695 ± 104 kPa (101 ± 15
psi)
High Idle with the parking brake
Torque Converter Inlet
engaged at pressure tap (M) less - -
Relief Valve (Tier III)
than 660 ± 104 kPa (96 ± 15 psi)
(1)
N = Normal, M = Monitor, A = Action
PT Trakindo Utama COMPONENT CONDITION REPORT
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Relief Valve (Torque Converter Outlet) Pressure - Test and Adjust

Status(1) Description Specification Actual Comments
Torque Converter Outlet Relief High Idle at pressure tap
Valve (N)
N 54 psi OK
(High Idle Third Speed Forward 405 ± 70 kPa
Stall) (59 ± 10 psi)
(1)
N = Normal, M = Monitor, A = Action
Transmission Lubrication Oil Pressure - Test
Status(1) Description Specification Actual Comments
Low Idle with all brakes disengaged at
Transmission
pressure tap (L1) 4 psi OK
Lubrication
30 ± 14 kPa (4 ± 2 psi)
Transmission High Idle with all brakes disengaged at
N Lubrication pressure tap (L1) 31 psi OK
(Tier II) 210 ± 35 kPa (31 ± 5 psi)
Transmission High Idle with all brakes disengaged at
Lubrication pressure tap (L1) - -
(Tier III) 190 ± 35 kPa (28 ± 5 psi)
(1)
N = Normal, M = Monitor, A = Action
Transmission Clutch Pressure - Test
Status(1) Description Specification Actual Comments
Clutch Engagement at Relief
2585 ± 105 kPa
Pressure Setting of the Transmission - -
(375 ± 15 psi)
No. 1 Clutch through No. 4 Clutch
Clutch Engagement at Relief
2205 ± 205 kPa
Pressure Setting of the Transmission - -
(320 ± 30 psi)
No. 5 Clutch
(1)
N = Normal, M = Monitor, A = Action
Flywheel Lubrication Oil Pressure - Test
Status(1) Description Specification Actual Comments
Flywheel Lubrication Oil Low Idle at pressure tap (L2)
- -
Pressure 307 ± 69 kPa (45 ± 10 psi)
Flywheel Lubrication Oil High Idle at pressure tap (L2)
- -
Pressure (Tier II) 460 ± 104 kPa (67 ± 15 psi)
Flywheel Lubrication Oil High Idle at pressure tap (L2)
- -
Pressure (Tier III) 440 ± 104 kPa (64 ± 15 psi)
(1)
N = Normal, M = Monitor, A = Action
PT Trakindo Utama COMPONENT CONDITION REPORT
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Last Status:
• Machine Breakdown.

Summary,
- Based on the results of inspections and tests on the Transmission Over Heating Problem, several
abnormal conditions were found, several parts needed repair or replacement, and the problem could
be indicated by the Scavange Pump not working optimally or damage to the internal parts or
components. replace parts/components and carry out tests again to obtain results that comply with
standards

Suggestion:
• Transmission Main relief valve need to Adjust.
• 1ea 420-0748 Pump GP Gear (Transmission & Torque Converter) need to Repair/Replace with the
new one.
• Hose Transmission 1ea 431-4858 Hose As & 1ea 426-2453 Hose As need to replace with the new
one.
• Starting Motor Gasket need to installed.
• 1ea 3T-6471 Screen As T/C Scavenge & 1ea 9P-0214 Screen As T/C Scavenge need to installed.