PRODUCT SUPPORT PROGRAM FOR IMPROVING THE FRONT FRAME CENTERSHIFT WELDS ON CERTAIN 16M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR IMPROVING THE FRONT FRAME CENTERSHIFT WELDS ON CERTAIN 16M MOTOR GRADERS

Usage:

TEBE2953-00

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28Apr2015

V207
V208

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR IMPROVING THE FRONT FRAME CENTERSHIFT WELDS ON CERTAIN 16M MOTOR GRADERS
7050 7051		PS90478

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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 "PS90478" 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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The existing centershift welds on the 16M Motor Grader front frames are exhibiting reduced fatigue life in certain applications. If these welds are not repaired in a timely manner, damage to the frame top and bottom plates can result.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
16M	B9H00365, 520, 752-753, 783, 795, 845 R9H00167, 169-170, 173, 175-176

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*****Group 2*****
16M	R9H00359, 392, 539, 554, 583, 611, 669-670, 682-683, 750, 755

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	4J0520	SEAL-O-RING
1	4J5477	SEAL-O-RING-ORFS
1	5K9090	SEAL-O-RING-ORFS
11	6V8398	SEAL-O-RING-ORFS
3	7J9108	SEAL-O-RING-ORFS
1	7X0750	BOSS-WELD
1	7X0751	BOSS-WELD
1	7X0752	BOSS-WELD
4	8D2873	BAR
2	8D3065	STRIP
4	8D8572	BEARING-SLEEVE (After Failure Only)
4	8D9507	BEARING-SLEEVE (After Failure Only)
2	8T3734	BOSS-WELD
1	8T3851	BOSS-WELD
2	8T4935	BOSS-WELD
2	8T6462	BOSS-WELD
2	8W6182	PLATE
2	8W9072	STOP
8	9D6588	SEAL-PIN (After Failure Only)
8	9D6591	SEAL-PIN (After Failure Only)
4	9R3761	BOSS
2	9R9866	BOSS
1	1900544	BOSS
2	2667777	BOSS M10X1.5
1	2715097	STRIP
1	2715099	STRIP
1	2715100	STRIP
1	2715101	STRIP
4	3049245	BLOCK
1	3747160	PLATE
1	3747161	PLATE
1	3747162	PLATE
1	3747163	PLATE
1	4559757	PLATE
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.
*****Group 2*****
1	4J0520	SEAL-O-RING (After Failure Only)
1	4J5477	SEAL-O-RING-ORFS (After Failure Only)
1	5K9090	SEAL-O-RING-ORFS (After Failure Only)
11	6V8398	SEAL-O-RING-ORFS (After Failure Only)
3	7J9108	SEAL-O-RING-ORFS (After Failure Only)
1	7X0750	BOSS-WELD (After Failure Only)
1	7X0751	BOSS-WELD (After Failure Only)
1	7X0752	BOSS-WELD (After Failure Only)
4	8D2873	BAR (After Failure Only)
2	8D3065	STRIP (After Failure Only)
4	8D8572	BEARING-SLEEVE (After Failure Only)
4	8D9507	BEARING-SLEEVE (After Failure Only)
2	8T3734	BOSS-WELD (After Failure Only)
1	8T3851	BOSS-WELD (After Failure Only)
2	8T4935	BOSS-WELD (After Failure Only)
2	8T6462	BOSS-WELD (After Failure Only)
2	8W6182	PLATE (After Failure Only)
2	8W9072	STOP (After Failure Only)
8	9D6588	SEAL-PIN (After Failure Only)
8	9D6591	SEAL-PIN (After Failure Only)
4	9R3761	BOSS
2	9R9866	BOSS (After Failure Only)
1	1900544	BOSS (After Failure Only)
2	2667777	BOSS M10X1.5 (After Failure Only)
1	2715097	STRIP (After Failure Only)
1	2715099	STRIP (After Failure Only)
1	2715100	STRIP (After Failure Only)
1	2715101	STRIP (After Failure Only)
4	3049245	BLOCK (After Failure Only)
1	3747160	PLATE (After Failure Only)
1	3747161	PLATE (After Failure Only)
1	3747162	PLATE (After Failure Only)
1	3747163	PLATE (After Failure Only)
1	4559757	PLATE
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

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All units must have the centershift inspected for damage. Refer to the Service Manual as necessary and follow the procedure detailed in Special Instruction REHS8792 "Repair Procedure For The 16M Motor Grader Front Frame and Centershift Bracket", to inspect the condition of the front frame centershift.
If any problems are noted, weld repair the unit. Units requiring weld repair should have the bottom reinforcement installed per the special instruction.
Units that do not require weld repair may have the reinforcement installed at the discretion of the dealer. Low hour units operating in severe applications may benefit from installation of the reinforcement plate. Higher hour units which show no centershift damage requiring weld repair will have negligible benefit from the bottom reinforcement plate installation.
Units that already have a bottom reinforcement plate installed must have all of the welds on the reinforcement plate blended/sanded to provide a smooth and uniform appearance free of discontinuities or any readily visible starts and stops.
If a bottom reinforcement plate is already installed on the unit, it does not need to be cut off to be replaced with the new reinforcement plate.
All units equipped with the curved fishplates must be updated with the improved square fishplates per the special instruction.
All units will have specified centershift welds TIG dressed as detailed in the special instruction. If any units have the bottom reinforcement plate installed or already possess a bottom reinforcement plate; TIG dress the weld on this plate per the special instruction.

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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, 61-90 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 55.0-hour job for Group 1
Note: This is a 39 hour job to inspect the centershift area, install a bottom reinforcement plate, and apply a TIG dressing to the specified welds. Further repairs are allowed per the following allowances and can be applied independent of one another: -If any cracks are found during the inspection that require replacement of the fishplates, an additional 16 hours will be allowed to install new fishplates. -If parent material weld repairs are required in the top and/or bottom plates of the front frame, an additional 16 hours will be allowed. The maximum total repair time for this letter should not exceed 71 hours.

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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, 61-90 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 39.0-hour job for Group 2
Note: This is a 39 hour job to inspect the centershift area, install a bottom reinforcement plate, and apply a TIG dressing to the specified welds. Further repairs are allowed per the following allowances and can be applied independent of one another: -If any cracks are found during the inspection that require replacement of the fishplates, an additional 16 hours will be allowed to install new fishplates. -If parent material weld repairs are required in the top and/or bottom plates of the front frame, an additional 16 hours will be allowed. The maximum total repair time for this letter should not exceed 71 hours.