PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE TORSIONAL COUPLER BOLTED JOINT AND UPDATING TRANSMISSION PISTONS AND SEALS ON CERTAIN 16M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE TORSIONAL COUPLER BOLTED JOINT AND UPDATING TRANSMISSION PISTONS AND SEALS ON CERTAIN 16M MOTOR GRADERS

Usage:

TEBE0860-02

Show/hide table

24Jan2014

(Revised 02Jun2014)

K02C
K030
K031
K040
K042

Show/hide table

Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE TORSIONAL COUPLER BOLTED JOINT AND UPDATING TRANSMISSION PISTONS AND SEALS ON CERTAIN 16M MOTOR GRADERS
3279 3155 3170 3063		PS90357

Show/hide table

NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

Show/hide table

NOTE:	When reporting the repair, use "PS90357" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
NOTE:	The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

Show/hide table


NOTE:	This Revised Service Letter replaces the 24Jan2014 (Revised 27Mar2014) Service Letter. Changes have been made to Parts Needed, Action Required and Rework Procedure.

Show/hide table

TERMINATION DATE

31Jan2016

PROBLEM

Show/hide table

The existing torsional coupler to flywheel bolted joint can fail on certain 16M Motor Graders due to torsional spikes. The existing transmission piston lip seals can prematurely fail on certain 16M Motor Grades. If the existing 161-8313 Seal fails it can cause low or loss of clutch pressure on one of the clutches, most common failures occur on one of the directional clutches 1, 2, or 3.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
16M	B9H00118, 122, 171, 220, 223, 247-248, 261, 265, 340-341, 351-352, 379, 381, 386, 462, 466, 470, 606, 704, 718-719, 721, 761, 797 R9H00333, 504, 661, 664, 667, 838-839, 854-855, 875-876

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	1H6227	SEAL-O RING
1	1P3705	SEAL-RECTANGULAR
1	3E6785	SEAL-O-RING
1	3K0715	SEAL-O RING
1	4J0520	SEAL-O-RING
3	4J0522	SEAL-O-RING
2	4J0524	SEAL-O-RING
1	4J0527	SEAL-O-RING
1	4J5267	SEAL-O-RING
1	4J5477	SEAL-O-RING-ORFS
2	5K9090	SEAL-O-RING-ORFS
20	5M2894	WASHER-HARD
8	5P8247	WASHER-HARD
24	6I8911	DISC-FRICTION
28	6I8912	DISC-FRICTION
1	6V8397	SEAL-O-RING-ORFS
5	6V8398	SEAL-O-RING-ORFS
3	6V8400	SEAL-O-RING-ORFS
6	6V9746	SEAL-O-RING-ORFS
1	7J9108	SEAL-O-RING-ORFS
1	9H0846	SEAL-O RING
8	9X2053	BOLT-SELF
1	9Y8386	GASKET
20	1653930	BOLT-HEX HEAD
1	1654854	SEAL-O-RING
6	2468800	SPRING-WAVE
2	2468801	SPRING-WAVE
8	2907514	BOLT-HEX HEAD
1	3283655	ELEMENT AS-XMSN
1	3491435	KIT-DT GASKET
5	4151704	SEAL-O-RING
3	4200774	PISTON
2	4200775	PISTON
2	4200776	PISTON
1	4389578	FLYWHEEL AS
1	4398599	CPLG AS-TORNL
1	OIL	TRANS OIL-BULK [100L(26.4gal)](After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

Show/hide table

The transmission must be removed for torsional coupler inspection and
piston seal rework (if required). Torsional coupling hardware will be
replaced on all units. It is recommended that any machines having more
than 1000 hours have the torsional coupler replaced. The flywheel will
be inspected and only replaced in the event of damage or failure.
Transmission clutch friction discs will be replaced on all units that
require transmission rework. Clutch friction disc wear will be measured
on these units and the wave springs replaced only on clutches that
exhibit significant wear of the friction material.

A Product Status Report in ET must be generated for all units and
attached to the claim. Ensure the histogram data for both the Engine
ECM and Trans/Chassis ECM are selected and downloaded.

If the machine has lost use of multiple forward and reverse gears,
remove the magnetic transmission screens and check for metal debris
such as broken bolts and washers. Check the magnetic screen prior to
performing any diagnostic tests for the power train described in the
Testing and Adjusting, RENR8482. Some power train diagnostic tests
require the engine to be run. Running the engine may cause further
damage to the rear gear group and flywheel housing. Damage to the rear
gear group of the engine could result if the bolts that hold the
torsional coupler to the flywheel have failed. The transmission pump
supplies lubrication to the gears and bearings within the flywheel
housing. The transmission pump will not be operational if the torsional
coupling bolted joint has failed.

If the transmission screens contain only clutch material, running the
engine will not cause further damage to the rear gear group or flywheel
housing; however, contamination of the system will be reduced by
limiting machine run time.

Refer to Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-6000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
8001-10000 hrs, 37-48 mo	20.0%	20.0%	0.0%	0.0%	60.0%	80.0%

Show/hide table

NOTE: This is a 130.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
NOTE: An allowance for machining of the installed flywheel and coupler may be claimed not to exceed $500 per machine. NOTE: An additional 90.0 hours will be allowed if the letter is applied after failure, for flushing and cleaning out the lower works to remove contamination.

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Show/hide table

Refer to the Service Manual if/as necessary.

Remove the transmission as per D&A removal instructions, media number KENR6019

If the coupler has failed, any of the bolts have backed out completely (missing), or other physical debris was generated through failure of the coupling joint, the transmission, flywheel housing, and rear gear group must be inspected. D&A transmission, inspecting for resultant damage and obstructions / restrictions in oil lube passages. Replace worn parts per Reuse and Salvage Guidelines (refer to KENR6019, SEBF8091, SEBF8115, and SEBF8193). Inspect all gears for any signs of damage or cracks; pay particular attention to gear teeth and bearings. The transmission input shaft gears and engine rear gear group should be closely examined as they are most likely to sustain damage in the event of a coupler failure. Refer to Reuse and Salvage Guidelines, SEBF8193, Reusability of Drive Train Gears, Crack Detection section for appropriate methods to inspect these specific gears for possible cracks. Follow D&A instructions per KENR6017 to remove the flywheel and rear gear group. Inspect the flywheel housing for deep gouging, cracks, or other damage. Inspect the gears for damage; pay particular attention to the gear teeth and the bearings.
Replace parts as required.

If the existing 12-bolt 3813771 Torsional Coupler and 4179596 Flywheel are not damaged, these parts should be reworked to a 20-bolt torsional coupler to flywheel bolted joint. Follow special instruction "Procedure to Inspect and Update the Torsional Coupler on Certain 14M and 16M Motor Graders", media number REHS4299. Note: All hardware that mounts the torsional coupler and flywheel should be replaced.

In order to minimize machine downtime, the transmission pistons and seals should be reworked on all machines. Follow the procedure for component replacement outlined in Service Magazine "New Seal Rings and Pistons are Now Used in the Transmission Clutches for Certain 14M and 16M Motor Graders", media number SEPD1569. Replace transmission friction discs on these units. Reference Specifications, RENR8481, 14M and 16M Motor Graders Power Train, Transmission, for minimum clutch disc thickness specifications. Any clutch that has experienced failure of any clutch where a disc is
below minimum specified thickness requires replacement of the wave spring in that clutch. Note: if machines already had piston seals reworked, the transmissions do not need to be reworked.

Install transmission per D&A installation procedure, media number KENR6019.

If the coupler has failed, any bolts have backed out completely, or any other physical debris was generated through failure of the coupling joint, change transmission and differential oil according to OMM, reference media number SEBU7884, "Transmission and Differential Oil-Change. Cleaning of the transmission oil cooler and rear axle may be required if significant debris is generated.