PRODUCT SUPPORT PROGRAM FOR REPAIRING THE TRANSMISSION ON CERTAIN 525D, 535D, 545D, AND 555D WHEEL SKIDDERS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REPAIRING THE TRANSMISSION ON CERTAIN 525D, 535D, 545D, AND 555D WHEEL SKIDDERS
Usage:
TEBE4732-01
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24Jun2016
(Revised 17Oct2016)
U-327
A-247
D-289
O-286
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After Failure Only
PRODUCT SUPPORT PROGRAM FOR REPAIRING THE TRANSMISSION ON CERTAIN 525D, 535D, 545D, AND 555D WHEEL SKIDDERS
3073 3030 3101 3167 1375 3064 3160
PS53241
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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 Program can only be administered after a failure occurs.
The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53241" as the Part Number
and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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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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NOTE:
This Revised Service Letter replaces the 24Jun2016 Service Letter. Changes have been made to the Problem, Affected Product, Parts Needed, Action Required, Service Claim Allowances, and Rework Procedure.
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TERMINATION DATE
30Jun2017
PROBLEM
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The transmission may fail in certain 525D, 535D, 545D, or 555D Wheel Skidders. The torsional coupler may be impacted by debris ingression. If the transmission fails in one of the listed effected product, repair it using the parts listed for your machine serial number.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 8% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 8% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 8% 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.
If a failure occurs, please follow the Removal and Installation procedure in KENR7517 for the Torque Converter and Transmission.
Then follow the Disassembly & Assembly Procedure for the Torque Converter and Transmission in KENR7517.
If one of the listed machines experiences a transmission failure please have the dealer TC create a DSN/Product Health Service Request with the Dealer Expectation as "Product Inquiry / Informational" to document the failure.
Also please include the following information in the request:
Resolution Detail section: CPI Number 366145 Contact section: Dealer CC: Mayberry_Robert_F1@Cat.com Other info: Please included the transmission SN and Machine SN and Hours.
Next, CLOSE the request at the dealership. (Do NOT submit the request to Caterpillar).
Refer to the attached rework procedure to inspect the torsional coupler and install the 521-5553 plug.
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SERVICE CLAIM ALLOWANCES
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-6000 hrs, 0-48 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs, 49-60 mo
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
NOTE: This is a 101.0-hour job for Group 1
SERVICE CLAIM ALLOWANCES for loaner machine. The PS will provide Dealers $85 USD for each SMU that a loaner machine is used in the support of a D Series Skidder that is down due to a power train failure that requires more than 1 day to repair. The loaner serial number will need to be included in the PS claim. The loaner time must reasonable and limited to the time that it takes to repair the customer?s machine. After the repair, the customer/dealer is responsible for returning the customers machine and retrieving the loaner machine within 24 hours. The dealer will make every effort to maintain a responsible timetable on repairing the customer's machine and getting the loaner machine off loan. Transport of the loaner machine and/or machine being repaired is the responsibility of the customer or Dealer. There is no minimum time for a loan, but anything over 50 SMU needs to be supported by documentation.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-6000 hrs, 0-48 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs, 49-60 mo
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
NOTE: This is a 101.0-hour job for Group 2
SERVICE CLAIM ALLOWANCES for loaner machine. The PSP will provide Dealers $85 USD for each SMU that a loaner machine is used in the support of a D Series Skidder that is down due to a powertrain failure that requires more than 1 day to repair. The loaner serial number will need to be included in the PSP claim. The loaner time must reasonable and limited to the time that it takes to repair the customer?s machine. After the repair, the customer/dealer is responsible for returning the customers machine and retrieving the loaner machine within 24 hours. The dealer will make every effort to maintain a responsible timetable on repairing the customer's machine and getting the loaner machine off loan. Transport of the loaner machine and/or machine being repaired is the responsibility of the customer or Dealer. There is no minimum time for a loan, but anything over 50 SMU needs to be supported by documentation.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-6000 hrs, 0-48 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs, 49-60 mo
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
NOTE: This is a 101.0-hour job for Group 3
SERVICE CLAIM ALLOWANCES for loaner machine. The PSP will provide Dealers $85 USD for each SMU that a loaner machine is used in the support of a D Series Skidder that is down due to a powertrain failure that requires more than 1 day to repair. The loaner serial number will need to be included in the PSP claim. The loaner time must reasonable and limited to the time that it takes to repair the customer?s machine. After the repair, the customer/dealer is responsible for returning the customers machine and retrieving the loaner machine within 24 hours. The dealer will make every effort to maintain a responsible timetable on repairing the customer's machine and getting the loaner machine off loan. Transport of the loaner machine and/or machine being repaired is the responsibility of the customer or Dealer. There is no minimum time for a loan, but anything over 50 SMU needs to be supported by documentation.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Before the coupling is removed from the flywheel please take pictures of the area around the coupling and flywheel to document the amount of dirt. Below is an example.
Image1.1.1
Remove the coupling and take pictures of the face of flywheel and the back of the coupling. Below is an example.
Image1.2.1
Image1.2.2
The coupler must be secured in at least four location on a bench. The spacers should be placed under the flange surface of the coupling and then also bolted to the table. This will allow the back side of the coupling to rotate freely to allow proper testing.
Image1.3.1
Fabricate a bar per below with welded nut in the center and install the two drive shaft bolts. Install a socket on the center welded nut and apply 500Nm of torque with a torque wrench (use long torque wrench to provide easier leverage). See reference dims in the bottom right picture.
Image1.4.1
Image1.4.2
Install a socket on the center welded nut and apply 500Nm of torque with the torque wrench. Document if the coupling moves freely in both directions (minor movement, ~ 1-2 degrees or 0.1?) and record a video. If the coupling does not move freely, then contact Robert Mayberry.
Image1.5.1
Remove the 12 M10 bolts and disassemble the coupling by separating the center hub from the outer part. Clean the interior and exterior of the coupling and flywheel. Use a dry shop towel to clean the inside of the coupling. Do not clean with water or solvents
Image1.6.1
Image1.6.2
Reassemble coupling by re-installing the (12) M10 bolts and torque between 57 and 63 Nm. Bolts should have a light amount of oil under the bolt head and on the end of the threads. Do not use any lubrication on the coupler when re assembling. Care must be taken to avoid the axial bearing (item 3) being trapped between item 4 and the back-plate item 5. Bolts should be tightened in a star pattern, 12 o?clock, 6 o?clock, 3 o?clock etc.
Image1.7.1
Contact Robert Mayberry at Mayberry_Robert_F1@cat.com or 309-675-2398 with results of the inspection.
Coupling Plug Installation.
Step 1 - Flip coupling so that the backside is facing up
Step 2 - Place cap in the center of the coupling hole
Image1.9.1
Step 3 ? Evenly tap with a plastic mallet to seat the plug all the way. Step 4 ? Confirm plug is seated evenly
