A Quality Problem Is Identified on Friction Disc on Certain Caterpillar Products{3160} Caterpillar

Articulated Truck:

735 (S/N: B1N1-UP)

735B (S/N: T4P1-UP)

740 (S/N: AXM2154-UP; B1P1-UP)

740 EJECTOR (S/N: B1R1-UP; AZZ390-UP)

740B (S/N: L4E374-UP; T4R1-UP)

740B EJECTOR (S/N: T4S1-UP)

D400E Series II (S/N: APF1-UP; 8PS1079-UP)

Transmission:

TH55 - KRESS (S/N: KCH1-UP)

Off-Highway Truck/Tractor:

69D (S/N: 9SS1-UP)

769D (S/N: BBB1-UP; 5TR1-UP; 5SS1-UP)

770 (S/N: M7W1-UP; BZZ1-UP)

772 (S/N: RLB1-UP; J2M1-UP)

776B (S/N: 6JC1-UP)

776C (S/N: 2TK1-UP)

776D (S/N: 5ER127-UP; AFS1-UP)

777 (S/N: 84A1-UP)

777B (S/N: 4YC1-UP; 3NF69-UP)

777C (S/N: 4XJ1-UP)

777D (S/N: DCB1-UP; AGC1-UP; FKR1-UP; 3PR1-UP; 2YW105-UP; AGY1-UP)

777F (S/N: WTK1-UP; JRP1-UP; JXP1-UP)

784C (S/N: 2PZ1-UP)

785 (S/N: 8GB1-UP)

785B (S/N: 6HK1-UP)

785C (S/N: 1HW134-UP; APX1-UP; 5AZ1-UP)

785D (S/N: DMC1-UP; MSY1-UP)

786 (S/N: 81A1-UP)

789 (S/N: 9ZC1-UP)

789B (S/N: 7EK1-UP)

789C (S/N: 2BW1-UP)

793 (S/N: 3SJ1-UP)

793B (S/N: 1HL1-UP)

793C (S/N: CBR1-UP; 4AR1-UP; ATY1-UP; 4GZ1-UP)

793D (S/N: FDB1-UP)

793F (S/N: SSP1-UP)

795F Series AC (S/N: ERM1-UP)

Quarry Truck:

771D (S/N: BCA1-UP; 6JR1-UP; 6YS1-UP)

Road Reclaimer/Soil Stabilizer:

RM-350 (S/N: 5FK1-UP)

RM-350B (S/N: AXW1-UP)

RM-500 (S/N: ASW1-UP)

RM350B (S/N: 7FS1-UP)

SM-350 (S/N: 1RM1-UP)

Track-Type Skidder:

D4 TSKH Series II (S/N: 8ZF1-UP)

D4 TSKH Series III (S/N: 7PK1-UP)

D5 TSKH Series II (S/N: 7EG1-UP)

Track-Type Tractor:

D4H Series II (S/N: 8PB1-UP; 9DB1-UP; 2AC1-UP; 3AC1-UP)

D4H Series III (S/N: 8PJ1-UP; 9GJ1-UP; 4NK1-UP)

D5H (S/N: 1YD1-UP; 2SD1-UP)

D6H Series II (S/N: 8FC1-UP; 1KD1-UP; 2KD1-UP; 3ED1-UP; 4YF1-UP; 4GG1-UP)

D6H (S/N: 7PC1-UP; 8YC1-UP)

D8L (S/N: 4FB1-UP)

Underground Articulated Truck:

AD40 Series II (S/N: 1YZ1-UP)

AD45 (S/N: BKZ1-UP)

AD45B (S/N: CXM1-UP)

AD55 (S/N: ANW1-UP; DNW1-UP)

AE40 II (S/N: BLW1-UP; 1ZZ358-UP)

Wheel Loader:

980C (S/N: 13B1-UP; 2XD1-UP; 63X1-UP)

980F Series II (S/N: 5XJ1-UP; 4RN1-UP; 8JN1-UP)

980F (S/N: 8CJ1608-UP; 3HK1-UP)

980G Series II (S/N: AXG1-UP; AWH2559-UP; AYT1-UP)

980G (S/N: 9CM1-UP; 2KR1-UP; 2SR1-UP)

988B (S/N: 50W1-UP)

988F (S/N: 8YG1-UP)

Wheel Tractor-Scraper:

627E (S/N: 6FB1-UP; 6HB1-UP; 3WJ1-UP)

627F (S/N: 4YK1-UP; 1DL1-UP)

627G (S/N: AXF1-UP; AYK1-UP; CEX1-UP; CEZ1-UP)

627H (S/N: LCT1-UP; DBW104-UP)

637E Series II (S/N: 1HB1-UP; 7CB1-UP)

637G (S/N: CEH1-UP; DFJ1-UP; AXT1-UP; DEY209-UP)

Introduction

The problem identified below has a known permanent solution.

Problem

The grooves in the friction discs are not properly machined and the friction discs have debris in the grooves that will contaminate the oil. Additionally, there is no chamfering on the outside diameter edge of the friction disc. Refer to Illustration 1 that shows debris in the grooves.

Illustration 1	g02276774
Debris on the grooves

Solution

Visually inspect the friction discs for correct machining of the grooves and verify that there is no debris. Do not use the friction discs if the friction discs have debris in the grooves or are improperly machined. Refer to Illustration 2, 3, and 4 that show friction discs with acceptable and non-acceptable grooves. Illustration 5 shows the "normally tapered" spiral groove in the friction disc with a spiral groove pattern.

If a friction disc does not meet the requirements shown, then the friction disc should be rejected and sent for rework.

Note: All friction discs in current production and all friction discs in stock have been inspected, and if necessary, reworked.

Use the solution for the part numbers that are listed in Table 1.

Illustration 2	g02317336
(A) Acceptable grooves (B) Not acceptable grooves

Illustration 3	g02276833
Acceptable grooves on the friction disc

Illustration 4	g02276834
Non-acceptable grooves on the friction disc

Illustration 5	g02317339
View of the spiraled grooves on the friction disc