PRODUCT SUPPORT PROGRAM FOR REPLCING THE SPEED SENSORS MOUNTED TO THE TRANSMISSION ON CERTAIN D5M AND D6M TRACK TYPE TRACTORS

Usage:

Caterpillar: Confidential Yellow

PRODUCT SUPPORT PROGRAM FOR REPLCING THE SPEED SENSORS MOUNTED TO THE TRANSMISSION ON CERTAIN D5M AND D6M TRACK TYPE TRACTORS

SEBE7272-03

April 20, 2000
(Revised July 2001)
U-122
A-97
AU-73
S-56
H-41
O-108

Show/hide table

*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPEED SENSORS MOUNTED TO THE TRANSMISSION ON CERTAIN D5M AND D6M TRACK TYPE TRACTORS
3175		PS40125

NOTE: This Program can 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 "PS40125" as the Part number and "7755" as the Group Number. If adminstered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If adminstered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

NOTE: This Revised Service Letter replaces the April 20, 2000 (Revised September 2000) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

December 31, 2001

PROBLEM

Certain D5M and D6M Track Type Tractors with electronic transmission controls have experienced problems with speed sensors mounted to the transmission. These problems can generate fault codes, can effect shift feel, and can prevent transmission calibration.

AFFECTED PRODUCT

Model Identification Number

D5M 6GN1-1536, 1538-1627

3CR1-977, 979-1107, 1110-1113, 1115, 1116, 1118, 1119, 1123-1127, 1130-1134, 1137, 1139, 1141, 1142, 1145-1156, 1158-1161, 1163, 1165-1169, 1171, 1173-1176, 1179, 1181, 1182, 1184, 1186-1199, 1201, 1203, 1204, 1206-1208, 1210-1223, 1230-1244

7LR1-352

5ES1-934

6AS1-462

D6M 3WN1-1596, 1598-1899, 1901-1912, 1914-1984, 1987, 1989-1997, 1999-2002,2005, 2007-2038, 2040-2050, 2052, 2053, 2056, 2061, 2062, 2064-2087, 2091-2094, 2097-2114, 2117-2122, 2125-2169

4JN1-1599, 1601-1778, 1781-1873, 1875-1876, 1881-1893, 1895-1974

6LR1-504

5NR1-415

4HS1-615

PARTS NEEDED

Note: The 1112427 CLIP AS-CONN is required only on the following serial number ranges: 6GN1-646, 3CR1-377, 7LR1-235, 5ES1-263, 6AS1-147, 3WN1-779, 4JN1-495, 6LR1-429, 5NR1-271 AND 4HS1-431. 1 - 1112427 CLIP AS-CONN
5 - 1932550 Sensor Gp-SP
2 - 0S1585 CAP SCREW

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

***** Affected Product *****

Show/hide table

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
0-5000	100%	5.0	0	0	0	0
NOTE: This is a 5.0- hour job. NOTE: If affected product is equipped with a winch, an additional 5 hours will be allowed to remove and install the winch. If affected product is equipped with a ripper, an additional 2 hours will be allowed to lower the ripper. If the affected product is equipped with a drawbar, an additional 1 hours will be allowed to remove and install the drawbar. Note: If affected product is equipped with a winch, and if performing another program at the same time this work is performed, the labor time required for winch removal and installation will only be allowed once.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Attach. (1 - Rework Procedure)

Rework Procedure

Speed sensor failure can result in the following fault causes:
FAULTS - 671FMI02, 672FMI02, 673FMI02, 674FMI02, or 675FMI02

Note: For D5M/D6M machines, the drive shaft is more easily accessed through the floor plate.

Note: For ripper equipped machines, the ripper does not need to be removed. Instead, follow steps 1 through 4 below:

1. Remove ripper shanks to be able to lower ripper to lowest position out of the way.

2. Lower ripper to lowest position at location that work is to be performed.

3. Shut off engine and move ripper hydraulic control several times to relieve any residual pressure in ripper circuit.

4. Disconnect ripper hose at back of tractor for hoist clearance to remove transmission. Cap off hoses to maintain system cleanliness.

PROCEDURE:

Remove the transmission according to the Transmission Disassembly and Assembly Service Manuals Listed Below:

D5M SENR8487
D6M SENR8387

Remove all 4 speed sensors mounted to the transmission.
Install 4 new speed sensors to the transmission.

Place transmission in horizontal position, with input and output shafts parallel to the floor.
Center the gear tooth in the sensor mounting hole
Screw the sensor in until the sensor tip touches the gear tooth
Counter rotate the sensor by 1/2 turn (180 degrees)
Carefully lock the sensor in this position by tightening the locknut to 25+/-5nm. When tightening the locknut, take care to prevent further sensor rotation.

Remove the speed sensor mounted to the torque converter.
Install a new speed sensor to the torque converter, following steps B through E indicated under #3 above.
Some D5M and D6M transmissions have had a shipping guard left on at the factory when the transmission was installed. This guard was installed to protect the speed sensors during shipping and storage. This bracket is not needed after the machine has been assembled, and can hinder access to the transmission speed sensors from below the operator's seat. While the transmission is removed from the machine, perform the following procedure to improve future speed sensor access. Remove the 112-6290 shipping guard (near the output speed sensors) and the two 1A-1460 Cap Screws holding it in place. In their place, install two new OS-1585 Cap Screws. These bolts should be tightened to 105 ± 20 N$ m (78 ± 15 lb ft). Reference Service Magazine, SEPD0506, Dated January 24, 2000, Page 15.