Product Support Program For Updating The Torque Converter And Transmission On Certain 928F And 938 Loaders And IT28F Tool Carriers Caterpillar

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.

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS8317" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

Problem

The torque converter cover may fail resulting in low performance or overheating and/or the transmission clutch hub sleeve bearings may not provide acceptable life on certain 928F and 938 Loaders and IT28F Tool Carriers.

Affected Product
Model & Identification Number

Group 1

928F (8AK391-443, 8AK445, 8AK447, 8AK451-453, 8AK455-459, 8AK464, 8AK470, 8AK562 2XL876 , 2XL877, 2XL887, 2XL889-891, 2XL893-916, 2XL918-936, 2XL938-946, 2XL965, 2XL969, 2XL974, 2XL1387)

IT28 (1JL171-176, 1JL178-190, 1JL195, 1JL197, 1JL199, 1JL234 3CL849 , 3CL861-863, 3CL865, 3CL866, 3CL868-875, 3CL877-880, 3CL882-914)

Group 2

938 (1KM273, 1KM274, 1KM285, 1KM287-291, 1KM295-297, 1KM299-381, 1KM383-387 2RM149-163 , 2RM165-190, 2RM192, 2RM198, 2RM200, 2RM210, 2RM212, 2RM476)

Parts Needed

2 - 8C5176 Seal-O-Ring

5 - 8E3416 Bearing-Sleeve

1 - 8E3433 Bearing-Sleeve

1 - 8E3435 Bearing-Sleeve

1 - 5F8000 Seal-O-Ring

1 - 1H6227 Seal-O-Ring

1 - 2H3088 Seal-O-Ring

1 - 3J1907 Seal-O-Ring

2 - 4J0520 Seal-O-Ring

1 - 6J2680 Seal-O-Ring

5 - 5K9090 Seal-O-Ring

1 - 2M2561 Seal-O-Ring

1 - 2M9780 Seal-O-Ring

1 - 1P3707 Seal-Rectangular

1 - 1S3311 Ring-Retaining

10 - 3S2093 Strap-Cable

1 - 1T2018 Cover

1 - 9T5916 Filter-Oil

1 - 1U8846 Gasket Maker

11 - 6V8397 Seal-O-Ring

6 - 1270576 Coil Assembly (Group 1 only)

6 - 1270577 Coil Assembly (Group 2 only)

Action Required

See attached rework procedure.

Service Claim Allowances

NOTE: This is a 30-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

1. Remove the transmission from the machine.

2. Replace the existing 1T1795 Cover on the front of the machine with a new 1T2018 Cover, 1S3311 Snap Ring and 2M2561 Seal-O-Ring. The O-ring seal goes under the cover to make sure the cover does not rotate.

3. Disassemble the transmission following the instructions in the service manual. Replace all sleeve bearings in the clutch hubs after polishing the sleeve bearing journals on the clutch shaft to a surface finish similar to that of an engine crankshaft journal or wrist pin. Both sleeve bearing journals on each of the three clutch shafts must be polished as follows:

A. Disassemble each clutch group to the basic shaft assembly.

B. Put a center in the chuck jaws of a lathe and a live center in the tailstock.

C. Mount the shaft between the centers of the lathe.

NOTE: Do not chuck on the shaft or use a drive dog as it may damage the surface.

D. Start the polishing operation using 1U8282 Emery Paper and several drops of oil. Run the lathe at approximately 500 RPM. To improve the polishing efficiency, oscillate the emery paper across the journals while the shaft is rotating. Continue the process for a minimum of 5 minutes. The shaft size will not be changed and you can not over-polish the journal.

NOTE: Use the Caterpillar emery paper listed as other emery paper may not produce the same results.

E. Stop the lathe and wipe the journals off with a clean towel. Repeat Step D using 1U8283 Emery Paper for a minimum of 5 minutes.

F. Repeat Step E using 4C8510 Crocus Cloth for a minimum of 5 minutes.

G. After polishing, be sure to wash the shafts and flush the lube passages.

4. Replace all hub sleeve bearings.

5. Assemble the clutch groups and test for leaks by applying air pressure in the hole next to the rotating seals.

6. Finish assembling the transmission.

7. Install the transmission back into the machine.

Group1

Replace the six existing 9X7876 Solenoid Coils on the transmission control with six new 1270576 Coils. Tighten the coil assembly nuts to a torque of 20 ± 2.5 N·m (15 ± lb. ft.). Be careful not to over tighten the bolts as the coils may be damaged.

Group 2

Replace the six existing 3E8588 Solenoid Coils on the transmission control with six new 1270577 Coils.Tighten the coil assembly nuts to a torque of 20 ±2.5 N·m (15 ± lb. ft.). Be careful not to over tighten the bolts as the coils may be damaged.