PRODUCT SUPPORT PROGRAM FOR REPLACING THE O-RING SEAL AND TEFLON SEAL RING ON CERTAIN 14M MOTOR GRADER TRANSMISSION CLUTCH PISTONS AND SHAFTS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE O-RING SEAL AND TEFLON SEAL RING ON CERTAIN 14M MOTOR GRADER TRANSMISSION CLUTCH PISTONS AND SHAFTS

Usage:

TEBE4884-00

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23Jun2016

Q301
Q303

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE O-RING SEAL AND TEFLON SEAL RING ON CERTAIN 14M MOTOR GRADER TRANSMISSION CLUTCH PISTONS AND SHAFTS
3155 3063 3170		PS90608

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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 "PS90608" 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

30Jun2017

PROBLEM

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Premature wear may be experienced by the transmission clutches;
clutches 1, 2, and 3 are more likely to be affected. Assembly damage to the piston seals can result in premature clutch wear that is likely to occur at 1500 hours or less.

Note: Improper seal installation can result in premature seal failure and clutch wear. Proper seal installation procedures can eliminate the risk of seal damage during installation. Reference the steps outlined in the rework instructions to ensure proper seating and installation of the piston seals and shaft seals.

AFFECTED PRODUCT

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Model	Identification Number
14M	R9J01405, 1407, 1413, 1432, 1475, 1477, 1492

PARTS NEEDED

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Qty	Part Number	Description
1	1H6227	SEAL-O RING
1	1P3705	SEAL-RECTANGULAR
1	1S9799	SEAL-O RING
1	3E6785	SEAL-O-RING
1	3K0715	SEAL-O RING
1	4J0520	SEAL-O-RING
7	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
6	5K9090	SEAL-O-RING-ORFS
24	6I8911	DISC-FRICTION (After Failure Only)
8	6V8397	SEAL-O-RING-ORFS
8	6V8398	SEAL-O-RING-ORFS
3	6V8400	SEAL-O-RING-ORFS
7	6V9746	SEAL-O-RING-ORFS
4	7J9108	SEAL-O-RING-ORFS
1	9X7380	SEAL-O-RING
1	9X7381	SEAL-O-RING
1	9Y8386	GASKET
28	1630343	DISC-FRICTION (After Failure Only)
2	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 (After Failure Only)
6	4426257	SPRING-WAVE (After Failure Only)
1	4642399	PISTON (After Failure Only)
3	4663019	PISTON (After Failure Only)
2	4663025	PISTON (After Failure Only)
2	4663030	PISTON (After Failure Only)
1	OIL_BULK	TRANS OIL - 100L (26.4 Gal) See OMM
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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Refer to the Service Manual if/as necessary and see the attached Rework Procedure.

Reference: Service Magazine, SEPD1569, "New Seal Rings and Pistons Are Now Used in the Transmission Clutches for Certain 14M and 16M Motor Graders"

Reference: Operational and Maintenance Manual,SEBU7883, "Transmission/Drive Train Oil"

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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%
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
8001-10000 hrs, 49-60 mo	20.0%	20.0%	0.0%	0.0%	60.0%	80.0%

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NOTE: This is a 85.0-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: In the event of an after failure repair, an additional 25.0 hours is allowed for cleaning of components, for a total 110.0 hours.

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PARTS DISPOSITION

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

Rework Procedure

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Machine electronic data, measurements/condition of internal transmission components, and general machine/component information must be recorded and submitted with the claim.

Record the machine serial number, transmission serial number, component hours, and specific lubricants used in the transmission (weight and brand).

Prior to removing the transmission for rework, collect a PSRPT (with Engine ECM and Trans/Chassis ECM histogram data), the clutch calibration history, the inching pedal histogram data, and clutch pressure measurements.

To download the clutch calibration data, using ET connect to the machine and select the transmission ECM. Under the ?Information? menu, select the ?Data Transport? option. Check only the two boxes titled ?Transportable Data? and ?Calibration History?. Select [Save to File] at the bottom of the display screen. Select an appropriate location to save the file and select [Save]. Once a dialog box appears and displays ?Offboard Data Saved Successfully? select [OK].

To download the inching histogram data, using ET connect to the machine and select the transmission ECM. Under the ?Information? menu, select the ?Data Transport? option. Check all three boxes titled ?Transportable Data?, ?Calibration History?, and ?Histogram?. Select [Save to File] at the bottom of the display screen. Select an appropriate location to save the file and select [Save]. Once a dialog box appears and displays ?Offboard Data Saved Successfully? select [OK].

Clutch pressure measurements must be taken both prior to removing the transmission and after the transmission is inspected and repaired. Refer to Testing and Adjusting 14M Motor Graders Power Train, Transmission Pressures ? Test and Adjust, RENR8482. Record all of the clutch pressure measurements shown in Table 1 and report these with the claim.

The transmission must be removed and disassembled in order to inspect for the presence of seal damage and/or possible clutch wear. If any of the clutch pressures are low or the machine has lost the use of any forward or reverse gears, remove the magnetic transmission screens and look for clutch material or other debris that may indicate an internal failure. If an internal failure is discovered, cleaning of the transmission cooler or rear axle may be required. Refer to Disassembly and Assembly Instructions, Transmission ? Remove, KENR6019 to remove the transmission from the unit.

All clutches and piston seals will be inspected as part of this rework. Disassemble the transmission; Refer to Disassembly and Assembly Instructions, Transmission ? Disassemble, KENR6019.
Measure all of the clutch disc thicknesses as they are disassembled; record the disc thicknesses and associated clutch, and report these values and associated clutch number with the claim.
Refer to Reuse and Salvage Guidelines, Transmission Clutch Plates and Disc Assemblies with Cellulose Friction Material, SEBF8115.
If any of the discs do not meet reuse guidelines with respect to thickness, replace all of the friction material within that clutch.
Measure the thicknesses of the new friction discs prior to installation, record these values, and report these values and associated clutch number with the claim.
Inspect the clutch disc hubs for any signs of stepping. If stepping is noted, replace the clutch disc.
Inspect the splines on the mating gear for wear. The thickness measurements of all clutch discs being removed and those being reinstalled into the clutch packs must be recorded by clutch number and submitted with the claim.

Inspect all clutch pistons and seals for any twisting or rolling of the seal. Refer to the below illustrations for two examples of twisted/damaged seals. Report any damaged/twisted seals and associated clutch number with the claim submission.

Note: Clutch 7 uses a lip type seal on the OD of the piston that is different than the other clutches. Inspect this seal for degradation on the lip of the seal.

Image1.3.1

Prior to replacing the piston seals, inspect the piston ID for scuffing. If a ridge on the piston ID bore is present, (if a finger nail can be caught on the defect), replace the piston.

Replace Teflon Piston Seals Using the Following Procedure:

Note: The following procedure is applicable to transmission clutches built with the Teflon seal rings on the pistons and shafts. If the Teflon seal rings are not currently installed on the pistons then, refer to Service Magazine, SEPD1569, "New Seal Rings and Pistons are Now Used in the Transmission Clutches for Certain 14M and 16M Motor Graders" to update the needed transmission components to allow use of the improved seals.

Note: The assembler must wear gloves to prevent injury while performing this rework.

1. Remove all piston seals and shaft seals.

2. Lubricate the shaft and shaft seal groove with transmission differential oil as specified in the Operation and Maintenance Manual for your machine.

Image1.4.1

3. Lubricate O-ring seal (6) and install O-ring seal (6) into the shaft groove by hand.

4. Lubricate Teflon seal ring (5) using transmission differential oil as specified in the Operation and Maintenance Manual for your machine.

5. Install Teflon seal ring (5) into the groove 50% of the way around the shaft by hand. Finish the installation into the seal groove using the proper straight, smooth tipped installation tool seal pick (AA).
Refer to Illustration 1.5.1.

Note: Do not overstretch Teflon seal ring (5).

Image1.5.1

6. Carefully install the pick between Teflon seal ring (5) and the shaft. Gently guide the pick around the shaft to engage Teflon seal ring (5) properly into the groove as shown above.

7. Apply pressure with thumb around the shaft groove. This procedure ensures that Teflon seal ring (5) is properly seated with no rolling or flaring of Teflon seal ring (5).

8. Lubricate the seal groove and piston with transmission/differential oil as specified in the Operation and Maintenance Manual for your machine.

9. Install O-ring seal (3) in the seal groove by hand.

10. Lubricate Teflon seal ring (4) using transmission/differential oil as specified in the Operation and Maintenance Manual for your machine.

Image1.6.1

11. Place the 426-2786 Seal installation tool (BB) on the top of the piston making sure it is seated. This is mandatory that the dealer uses this 426-2786 tool to install the Teflon seals, in order to minimize the stretch and reduce chances of scratching/cutting, marring of the teflon seals during installation.

Image1.7.1

12. Install the seal ring onto the seal installation tool, then cupping your hands around the guide, slide the seal down the guide until the seal slips into the ring groove.
Refer to Illustration 1.7.1 for proper hand placement.

Image1.8.1

13. Remove the seal installation tool and Spin the piston several times while applying pressure with thumb to Teflon seal ring (4). This procedure ensures a proper seat with no rolling or flaring of the Teflon seal ring.

Image1.9.1

Image1.9.2

14. Visually inspect Teflon seal ring (4) to ensure that Teflon seal ring (4) is seated squarely in the groove of the piston. Refer to Illustration 1.9.1. If the seal is canted in the groove, as shown in Illustration 1.9.2, the seal may be damaged during installation into the cylinder. Repeat Teflon seal ring assembly procedure until the Teflon seal ring is squarely seated.

15. Apply transmission/differential oil as specified in the Operation and Maintenance Manual to the following:
- Shaft-side piston pocket OD
- Shaft seal and lands ID
- The piston

16. Lower the piston into the cylinder using your hands only.

Image1.10.1

17. Seat the piston into the bottom of the cylinder by pressing indicated-areas. Press the three areas in a circular continuous (B), (C) and (D) three point pattern. Perform this action until the piston is fully seated.

18. After completing the assembly of the shaft, use a soft tipped blow gun to pressure test the assembly. Apply air pressure of less than 150 PSI to the clutch pressure ports on the end of the shaft.

19. If leakage is detected, disassemble the clutch, remove the piston, and inspect the clutch and piston for the cause of the air leak.
Reassemble the piston and clutch according to the above instructions and retest.

Prior to assembling the shafts back into the transmission case, inspect the case bores for damage. Please refer to Special Instruction REHS8790 to have further information and repair procedure, in case of bore concern.

Reinstall the transmission in the machine. Refer to Disassembly and Assembly Instructions, Transmission ? Install, KENR6019.

Perform a Transmission Fill Calibration.

Clutch pressure measurements must be taken after the transmission is inspected and repaired. If this was not done on a test bench, record the clutch pressure measurements. Refer to Testing and Adjusting 14M Motor Graders Power Train, Transmission Pressures ? Test and Adjust,RENR8482. Record all of the clutch pressure measurements shown in Table 1 and submit these with the claim.

Collect a second PSRPT (with Engine ECM and Trans/Chassis ECM histogram data) after all repairs, tests, and calibrations are complete.
Submit this PSRPT with the claim.