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:

TEBE1412-02

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04Jun2014

(Revised 12May2015)

T070
T080
U067
U069
U245
Y500

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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 1156 1158		PS44333

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44333" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 04Jun2014 (Revised 15Apr2015) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Oct2015

PROBLEM

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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

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Model	Identification Number
*****Group 1*****
16M	B9H00842 R9H00655, 657, 738, 775, 826, 828, 831, 887

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*****Group 2*****
16M	B9H00147, 242, 272, 399, 407-408, 423, 465, 643, 648, 774, 841 R9H00139, 142, 172, 196, 202, 242, 376, 406, 425, 428, 435, 511, 541, 754, 772, 774, 776, 780-782, 784-785, 788-789, 797-798

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*****Group 3*****
16M	R9H00122, 410, 424, 430-431, 433, 534, 564, 566, 644

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
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 (After Failure Only)
28	6I8912	DISC-FRICTION (After Failure Only)
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
2	2468801	SPRING-WAVE (After Failure Only)
8	2907514	BOLT-HEX HEAD
1	3283655	ELEMENT AS-XMSN (After Failure Only)
1	3491435	KIT-DT GASKET (After Failure Only)
5	4151704	SEAL-O-RING (After Failure Only)
1	4389578	FLYWHEEL AS
1	4398599	CPLG AS-TORNL
6	4426257	SPRING-WAVE (After Failure Only)
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 25% 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.
*****Group 2*****
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
2	2468801	SPRING-WAVE (After Failure Only)
8	2907514	BOLT-HEX HEAD
1	3283655	ELEMENT AS-XMSN
1	3491435	KIT-DT GASKET
5	4151704	SEAL-O-RING
1	4389578	FLYWHEEL AS
1	4398599	CPLG AS-TORNL
6	4426257	SPRING-WAVE (After Failure Only)
3	4663019	PISTON
2	4663025	PISTON
2	4663030	PISTON
1	OIL	TRANS OIL-BULK [100L(26.4gal)]
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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.
*****Group 3*****
24	6I8911	DISC-FRICTION
28	6I8912	DISC-FRICTION
1	9H0846	SEAL-O RING
2	2468801	SPRING-WAVE (After Failure Only)
6	4426257	SPRING-WAVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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

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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.

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SERVICE CLAIM ALLOWANCES

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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%
*****Group 1*****
0-6000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 73-84 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 55.0-hour job for Group 1 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: This is a 55 hour job to disassemble, inspect, rework, and reassemble machines with torsional couplers that have not experienced a failure where hardware or coupling components have detached. An additional 75 hours will be allowed to inspect and repair the transmission, flywheel housing, and rear gear group on units where hardware and coupling components have become detached for a total of 130 hours. An allowance for machining of the flywheel and coupler may be claimed not to exceed $500 per machine. If both the coupling and flywheel are being replaced with new components, this allowance does not apply.

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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%
*****Group 2*****
0-6000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 73-84 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 110.0-hour job for Group 2 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: This is a 110 hour job to disassemble, inspect, rework, and reassemble machines with torsional couplers that have not experienced a failure where hardware or coupling components have detached. An additional 20 hours will be allowed to inspect and repair the transmission, flywheel housing, and rear gear group on units where hardware and coupling components have become detached for a total of 130 hours. An allowance for machining of the flywheel and coupler may be claimed not to exceed $500 per machine. If both the coupling and flywheel are being replaced with new components, this allowance does not apply.

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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%
*****Group 3*****
0-6000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 73-84 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 0.0-hour job for Group 3 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.
Support is provided for this group for parts only. No labor or miscellaneous costs may be claimed. These updates are to be executed in conjunction with other transmission updates.

PARTS DISPOSITION

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

Rework Procedure

Refer to Service Manual if/as necessary.

Remove transmission 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. Replace parts as required.

All machines will 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 must be replaced on these units. Also, all Group 3 machines will have the coupler and transmission reworked under a separate Priority Service Program; this Before/After Service Letter provides only the transmission friction discs and a transmission o-ring to be replaced in conjunction with executing that Priority Service Program. In the event a transmission clutch has failed or any clutch disc is below minimum specified thickness, the wave spring in that clutch will be replaced. Reference Specifications, RENR8481, 14M and 16M Motor Graders Power Train, Transmission, for minimum clutch disc thickness specifications.

If the transmission is being reworked on any unit, examine the transmission case bores for wear. Pay particular attention to the bores in which the shaft carriers are located. If damage to a bore is noted, reference Special Instruction ?Procedure to Rework the Case Bore on Certain Motor Grader Transmission Cases?, media number REHS8790, for the proper repair procedure.

Group 1 machines already have updated transmission piston seals installed. Unless this letter is being executed on an after failure basis, only the torsional coupler bolted joint will be updated.

Transmission pistons and seals will be reworked for all Group 2 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 clutch friction discs on all units. Reference Specifications, RENR8481, 14M and 16M Motor Graders Power Train, Transmission, for minimum clutch disc thickness specifications. Any clutch that has experienced a failure or any clutch where a disc is below minimum specified thickness requires replacement of the wave spring in that clutch. Note: if Group 2 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.