PRODUCT SUPPORT PROGRAM FOR INSPECTING MAJOR STRUCTURAL COMPONENTS ON CERTAIN 16M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING MAJOR STRUCTURAL COMPONENTS ON CERTAIN 16M MOTOR GRADERS

Usage:

TEBE2911-00

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28Apr2015

V207
V208

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSPECTING MAJOR STRUCTURAL COMPONENTS ON CERTAIN 16M MOTOR GRADERS
7057 7100 7050 7067 6153 4064		PS90475

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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 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.

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NOTE:	When reporting the repair, use "PS90475" 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.

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TERMINATION DATE

30Apr2016

PROBLEM

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On certain 16M Motor Graders, a structural inspection is recommended, on targeted areas, while performing other updates to reduce potential downtime to customers.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
16M	B9H00783, 795, 845 R9H00167, 169, 173, 359, 539, 554, 682-683, 750, 755

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*****Group 2*****
16M	B9H00365, 520, 752-753 R9H00170, 175-176, 392, 583, 611, 669-670

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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The major structural components on the 16M motor grader will be visually inspected for signs of excessive wear or damage. The components to be inspected include the drawbar, circle, moldboard, ripper, front frame, rear frame, front axle and tandem weldments.

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*****
0-18000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
18001-24000 hrs, 61-96 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 1
1 hour of Inspection and all rework time should be documented in the warranty claim associated with the service letter. In addition to the service letter warranty claim, each unique weld repair must also be documented in an individual SIMS record. Use the table above in Image 1 for proper SIMS reporting for each weld repair. Include detailed photos of the weld area needing repair in the SIMS record and reference PS9xxxxx in the comments.

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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*****
0-18000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
18001-24000 hrs, 61-96 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 1.0-hour job for Group 2
1 hour of Inspection and all rework time should be documented in the warranty claim associated with the service letter. In addition to the service letter warranty claim, each unique weld repair must also be documented in an individual SIMS record. Use the table above in Image 1 for proper SIMS reporting for each weld repair. Include detailed photos of the weld area needing repair in the SIMS record and reference PS9xxxxx in the comments.

PARTS DISPOSITION

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

Rework Procedure

The primary method of inspection for this procedure is visual inspection. Examine components for any gouging, paint cracking around welds, voids or fractures within or adjacent to any welds, or other obvious signs of damage. Note that paint cracking along a weld is not a definite sign of the presence of a crack but is an indication that damage may be present. Magnetic particle or dye penetrant methods may be used to confirm the existence of any cracks.

Note that if any repairs or parts are needed, the customer should be contacted with repair recommendations to determine the appropriate course of action. Proper repair methods are listed in the following procedure.

Inspect the ripper stop welded to the frame backing plate for signs of damage. Bending of the plates or cracks in the welds can develop when the machine is impacted from the rear or pushed with the ripper in the raised position. Inspect the welds at the corners of the upper link brackets for any signs of cracking (8 locations). Repair using general weld procedures, reference SEBD0512. Inspect the ripper pins/joints for signs of wear or loosening of the pins. Inspect ripper teeth for extreme wear.

Inspect tandem housing for signs of obvious damage. Inspect the lower horizontal welds on the tandem case for any cracks; oil seepage along these weld seams would indicate a crack is present. Inspect the two seams on each tandem on both sides of the machine (a total of four locations). If rear fenders are mounted to the machine, inspect the front and rear fender mounts for cracking or damage; updated fender mounts are shown for reference. Weld repair any damage using general weld procedures; reference SEBD0512.

Inspect rear frame. Starting at the rear, examine the welds between the rear rails and the bumper for sings of cracking. If possible inspect all four sides of the joint, both sides of the frame; this will be difficult with the ripper installed. Inspect the tandem oscillation stops for signs of damage or weld cracking. If any problems are noted, inspect the corresponding blocks on the tandems. Repair using general weld procedures; reference SEBD0512.

Inspect the rear frame welds between the rear rails and cast rails on both sides of the frame as shown. General weld procedures can be used to repair these welds; reference SEBD0512. Examine the rearmost pocket in the casting for any signs of cracks, again both sides of the frame. Inspect the top articulation pin retainer bolts for any signs of loosening or sheared or missing bolts. Problems with this bolted joint can indicate articulation hitch/bearing wear or damage to the top frame plate.

Inspect the weld toes on the wrapper plates adjacent to the top frame plate (see illustration) on both side of the frame. Use general weld procedures (reference SEBD0512) to make repairs. Be sure to blend grind/sand welds into the adjacent material to remove any discontiunities; finished welds should look uniform in appearance. If possible, TIG dress the weld toes at the end of the wrapper plate. Inspect the lower bushing in the upper hitch pin joint for any signs of movement in the lower plate of the upper joint. If the bushing is walking out, the hitch must be repaired using line bore procedures. Refer to Reuse and Salvage Guidelines, SEBF8401, "Dimensions for Articulated Joints and Steering Cylinder Bores for Motor Graders" for proper bore specifications. Inspect the lower pin bottom pin retainer for any signs of loose or missing bolts. Re-tighten the bolts to the proper torque as required.

Inspect the articulation lock pin bores for signs of damage. Holes should allow for proper fit of the locking pin without excessive movement. The bores should not be elongated and no deformation or damage to the plates should be present. Inspect the front frame lower side plate to bottom plate weld toes for any signs of cracking. Repair using general weld procedures; reference SEBD0512. Be sure to blend grind/sand welds to blend into adjacent material. If possible, TIG dress weld toes at the rear of the side plate.

Inspect the side plate to top plate welds at the rear of the front frame (both sides of frame). If any cracks are found, repair using general weld procedures. Reference SEBD0512. Be sure to blend grind/sand welds to blend into adjacent material. If possible, TIG dress weld toes at the rear of the side plate. Inspect weld between the front frame top plate and circular plate welded to the bottom of the top plate (see illustration). If cracking is noticed, repair using general weld procedures (SEBD0512). Ensure root of the weld crack is found; note that this may extend into the top plate of the front frame. If weld repair to the top plate is required, splitting of the front and rear frames may be required for weld access and to brace the top plate to prevent weld distortion.

Inspect the front frame centershift. The vertical welds on both ends of the front and rear fish plates (both sides of the frame) should be inspected for cracks. Inspect all welds around the front and rear centershift plates, again on both sides of the frame. If cracks are found, inspect the adjacent parent material for any signs of cracking to include the frame top and bottom plates. Additional details for inspection and repair procedures for the front frame centershift can be found in Special Instruction REHS8792 "Inspection and Rework Procedure for the 16M Motor Grader Front Frame Centershift".

Inspect vertical weld on the front frame side plate as well as the adjacent top and bottom plate welds in the vicinity of the vertical weld for any signs of cracking. Inspect the side plate to bottom plate weld where the frame curves down toward the bolster. Examine the transition area at the rear side of the bolster (reference circled area in below image) for signs of cracking. Both sides of the frame should be inspected. Repair using general weld procedures, SEBD0512. Be sure to blend grind/sand and repairs into the adjacent material.

Inspect the front frame above the link bar. Damage to the frame in this area indicates possible link bar issues or damage to the front axle oscillation stops. Inspect these areas/components and make repairs as needed. Inspect the bolster pins for signs of movement; there should be no relative motion between the bolster pins and the front frame. The pin retainer bolts should be snug and U-shaped plates that retain the pins welded firmly in place. If the bolster pins are moving in the frame bores, retainer plates may need to be rewelded/repaired, pins inspected, and possibly the bolster pin bores in the front frame repaired/line bored. Refer to Reuse and Salvage Guidelines, SEBF8401, "Dimensions for Articulated Joints and Steering Cylinder Bores for Motor Graders" for proper bore specifications.

Inspect the front axle weldment where the front gussets connect to the main axle body. Inspect the welds that wrap around the main axle body for signs of cracks (see welds indicated by dashed lines in image). Use general weld procedures (SPED0512) to repair welds and apply Special Instruction REHS8761, "Procedure to Install Gussets on the Front Axle Assembly on Certain 16M Motor Graders" if repairs to the gusset welds are required. Inspect all motion joints on the front axle for presence of grease. Apply a force to the tie rod ends in an upward/downward motion; no play should be noticed in this joint. Ensure tie rod boots are present and undamaged.

Inspect inboard steering cylinder mounts and pins for any signs of damage. Pin retention bolts should be tight. Inspect the spherical bearings for any cracking in the bearing cages or other damage. If the spherical bearings are damaged, inspect the bores in the axle body where they are installed for any signs of yielding or damage. If damage is present, reference Special Instruction REHS8757, "Instructions for Installing the Bracket Assembly for the Steering Cylinder on Certain 16M Motor Graders" for the proper repair procedure.

Inspect draft ball welds on drawbar (all three). Inspect drawbar beam to divider plate welds (shown with dotted lines in below image) on both sides of drawbar. Inspect welds on drawbar bottom plate just in front of circle. Note, the newer style drawbar with reoriented weld seams is shown. Older drawbars will have welds that run side to side underneath the drawbar beams and a possible reinforcement plate may be installed. All welds on the reinforcement plate should also be inspected if that component is present. If any weld cracks are present, use general weld procedures to repair; reference SEBD0512. All finished welds should be blend ground/sanded smooth in the adjacent material. If repairs are required for the reinforcement plate, refer to Special Instruction, REHS4235, "The Procedure to Repair the Drawbar on Specific Motor Graders". Note. If the reinforcement plate is not present, do not install this additional component. Also, if weld cracks were present, inspect the drawbar beams adjacent to the welds for any possible cracking. Inspect circle drive mounting bolts for any signs of loosening. If loose bolts are shown, inspect condition of threaded holes and repair as required. Re-tighten the mounting bolts to the proper torque.

Inspect welds on gussets on rear side of the drawbar for cracking. Repair using general weld procedures, SEBD0512. Inspect weld on tip cylinder mounting bracket on rear of circle (see below image). If any cracking is present, excavate the weld to find the root, weld repair, and blend grind/sand the finished weld into the adjacent material. No discontinuities or visible weld toes should be present on the ends of the mounting bracket.

Inspect welds at rear of circle where gussets are welded to blade beams. If any cracks are present, repair using general weld procedures, SEBD0512. Note that the welds stop 25mm from the end of the gussets; do not weld to the end of the gusset or a repeat weld failure will likely occur. Inspect tip cylinder pins for any signs of loosening or cracking of the flag pins. Inspect the moldboard bracket on the tube where the fittings for the sideshift cylinder protrude. There should be no cracking or gouging present on the circular cutouts. Inspect the eight retainer plates for the moldboard wear strips. These retainer plates should not come into contact with the moldboard rails. Shim moldboard wear strips as required to provide clearance between the retainer plates and the rails. Inspect the cutting edges for excessive wear.