PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FINAL DRIVE DUO-CONE SEALS ON CERTAIN AP-655C, AP-655D, AP-1000D, AP-1055D, AND BG-260D ASPHALT PAVERS
Usage:
REBE3353-01
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| 25Feb2008 |
| (Revised 08Apr2008) |
U-92
A-146
O-165
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| Priority | PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FINAL DRIVE DUO-CONE SEALS ON CERTAIN AP-655C, AP-655D, AP-1000D, AP-1055D, AND BG-260D ASPHALT PAVERS |
|
| 4050 7561 | PI31452 |
|
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| NOTE: | This Program must be administered as soon as possible. When reporting the repair, use "PI31452" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31452" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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 28FEB2008 Service Letter. Changes have been made to add Mail Codes and to the serial numbers in the Affected Product. |
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COMPLETION DATE |
TERMINATION DATE |
| 31Aug2008 | 28Feb2009 |
PROBLEM
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| The duo-cone seals for the propel final drives need to be replaced on certain AP-655C, AP-655D, AP-1000D, AP-1055D, and BG-260D Asphalt Pavers. The existing duo-cone seals can develop leaks. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| AP-1000D | EAD00245-00246, 249 |
| AP-1055D | FAC00545-00550, 556, 559 |
| AP-655C | AYP00365, 374 |
| AP-655D | GNN00202 GNZ00228, 230, 234-236, 239 |
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| *******Group 2******* | |
| AP-1000D | EAD00231, 242, 247-248, 250, 253-254, 256-257, 260-261 |
| AP-1055D | FAC00551-00555, 557-558, 560-562, 564-583 |
| AP-655D | GNZ00223-00227, 229, 237, 240-242 |
| BG-260D | BPW00126 |
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| *******Group 3******* | |
| AP-1055D | FAC00485 |
| AP-655D | GNN00203 |
| BG-260D | BPW00121 |
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| *******Group 4******* | |
| AP-1055D | FAC00405, 540 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 2 | 3254691 | SEAL-DUO CONE |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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. | ||
| *******Group 2******* | ||
| 1 | SEALGP | SHIPPED DIRECT TO DEALERS |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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. | ||
| *******Group 3******* | ||
| 1 | 3254691 | SEAL-DUO CONE |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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. | ||
| *******Group 4******* | ||
| 1 | 3254691 | SEAL-DUO CONE |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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| The duo-cone seals for the propel final drives need to be replaced. Refer to the section titled Rework Instructions for further information. Machines in Group 2 will not require parts to be ordered for the repair. Machines in Group 2 will have the new replacement duo-cone seals shipped directly to the dealers. If there are any questions regarding the parts for Group 2 machines contact Paul Shockman 763-493-1449. GROUP 1 MACHINES: Replace seals in BOTH final drives - 2 seals will need to be ordered. GROUP 2 MACHINES: Replace seals in BOTH final drives - parts were shipped direct to dealers. GROUP 3 MACHINES: Replace seals in the LEFT side final drive only - 1 seal will need to be ordered. GROUP 4 MACHINES: Replace seals in the RIGHT side final drive only - 1 seal will need to be ordered. |
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OWNER NOTIFICATION
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| U.S. and Canadian owners will receive the attached Owner Notification. |
SERVICE CLAIM ALLOWANCES
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| *******Group 1******* | |||||
| NOTE: This is a 24.0-hour job for Group 1 | |||||
| NOTE: An additional 7 hours will be allowed for track drive machines An additional 2 hours will be allowed for pavers with screeds attached |
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| *******Group 2******* | |||||
| NOTE: This is a 24.0-hour job for Group 2 | |||||
| NOTE: An additional 7 hours will be allowed for track drive machines An additional 2 hours will be allowed for pavers with screeds attached |
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| *******Group 3******* | |||||
| NOTE: This is a 16.0-hour job for Group 3 | |||||
| An additional 3.5 hours will be allowed for track drive machines An additional 2 hours will be allowed for pavers with screeds attached |
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| *******Group 4******* | |||||
| NOTE: This is a 16.0-hour job for Group 4 | |||||
| An additional 3.5 hours will be allowed for track drive machines An additional 2 hours will be allowed for pavers with screeds attached |
PARTS DISPOSITION
| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
| MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE. |
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| COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FINAL DRIVE DUO-CONE SEALS ON CERTAIN AP-655C, AP-655D, AP-1000D, AND AP-1055D ASPHALT PAVERS MODELS INVOLVED - AP-655C, AP-655D, AP-1000D, and AP-1055D Asphalt Pavers Dear Caterpillar Product Owner: The duo-cone seals for the propel final drives need to be replaced on the products listed below. The existing seals can develop leaks. You will not be charged for the service performed. Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated 25Feb2008 when scheduling this service. We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime. Caterpillar Inc. Identification #(s) Attached to 25Feb2008 Service Letter |
| Refer to the disassembly and assembly service manual modules referenced below. Pay special attention to the following important steps. 1) The shifters must be removed from the final drives. However, there is no need to disassemble the shifters. 2) The carrier must be separated prior to removal. Not separating the carrier prior to removal can result in damage to the thrust washers. Refer to illustration 1.1.2 3) The planet gears must be removed from the gear reducer for this repair. There is no need to separate the planet gears from the four shafts as shown in the disassembly process. Thread a bolt in the end of the four shafts and move the bolt side to side in order to free up the shafts. Keep the inner and outer thrust washers, gears, and shafts together when removing them. Not separating the gears from the shafts will keep the roller bearings secured in position. Refer to illustration 1.1.1 4) Follow the step-by-step instructions for the assembly of duo-cone seals per the referenced service manual modules. 5) The duo-cone seals are preserved and packaged in a way that will require them to be cleaned prior to assembly. Use isopropyl alcohol and a lint free cloth for this procedure. All components should be completely dry before proceeding with the assembly of the duo-cone seals. Inspect the duo-cone seals for damage prior to use. 6) The rubber toric portion of the duo-cone seal must NOT be lubricated. This portion of the duo-cone seal is designed to "roll" and not "slide" within the assembly. Any lubrication may result in the seal sliding instead of rolling which will cause the seal to fail. 7) Once the duo-cone seal halves are inserted into the housings, the mating machined surfaces of the steel rings must be lubricated with clean TDTO50 using a clean foam brush. Lubricate the entire mating surface on each of the steel rings. 8) Ensure the proper torque is applied to all fasteners during re-assembly. Bolted joints with multiple fasteners will require multiple passes with a torque tool in order to reach the proper clamp load. This will prevent the joint from loosening. Torque specifications are shown in the illustration below for bolted joints that do not use a standard torque value. Torque specifications for all other fasteners are specified Media Number -SENR3130-10 Torque Specifications for All Caterpillar Products. |
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| Image1.1.1 |
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| Image1.1.2 |
| Torque values for wheel drive machines Torque value for fasteners (A) 400 +/- 50 Nm (295 +/- 37 ft lbs) Torque value for fasteners (B) 400 +/- 50 Nm (295 +/- 37 ft lbs) Torque value for fasteners (C) 560 +/- 60 Nm (413 +/- 44 ft lbs) |
|
| Image1.2.1 |
| Torque values for track drive machines Torque value for fasteners (D) 530 +/- 70 Nm (390 +/- 52 ft lbs) Torque value for fasteners (E) 460 +/- 60 Nm (340 +/- 44 ft lbs) Torque value for fasteners (F) 560 +/- 60 Nm (413 +/- 44 ft lbs) |
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| Image1.3.1 |
| 9) Ensure the propel motors are installed on the side in which they were removed. 10) Prior to installing the tracks or the wheels on the machine operate the propel system. Cycle the propel system in the following sequence: Forward, low engine idle, pave mode, full propel for 10 minutes Reverse, low engine idle, pave mode, full propel for 10 minutes Forward, low engine idle, travel mode, full propel for 10 minutes Reverse, low engine idle, travel mode, full propel for 10 minutes Inspect the planetary for any leaks prior to proceeding. 11) After the machine is returned to an operational condition, verify the machine tracks straight as noted in the "Pump Synchronization" test located in the test and adjust manuals. Also, verify the machine initial current calibrations are correct by checking for skewing when propelling the machine as noted in the propel systems troubleshooting manuals. |
| NOTE: Reference the following service manual modules for disassembly and assembly for the respective machine models: AP-655C Disassembly and Assembly AP-655C Asphalt Pavers Machine Systems Media Number -KENR5033-00 Screed - Remove and Install Tow Arm - Remove and Install Belt - Remove Wheel (Final Drive) - Remove and Install Final Drive Planetary - Remove Final Drive Planetary - Disassemble Duo-Cone Conventional Seals - Install Final Drive Planetary - Assemble Final Drive Planetary - Install Belt ? Install AP-655D Disassembly and Assembly AP655D Asphalt Pavers Machine Systems Media Number -KENR6002-00 Screed - Remove and Install Tow Arm - Remove and Install Belt - Remove Wheel (Final Drive) - Remove and Install Final Drive Planetary - Remove Final Drive Planetary - Disassemble Duo-Cone Conventional Seals - Install Final Drive Planetary - Assemble Final Drive Planetary - Install Belt - Install AP-1000D Disassembly and Assembly AP-1000D and BG-260D Asphalt Pavers Media Number -KENR5069-00 Screed - Remove and Install Tow Arm - Remove and Install Wheel (Rear) - Remove and Install Final Drive Planetary - Remove Final Drive Planetary - Disassemble Duo-Cone Conventional Seals - Install Final Drive Planetary - Assemble Final Drive Planetary ? Install AP-1055D Disassembly and Assembly AP-1055D and BG-2455D Asphalt Pavers Machine Systems Media Number -KENR5048-00 Screed - Remove and Install Tow Arm - Remove and Install Belt - Remove Wheel (Final Drive) - Remove and Install Final Drive Planetary - Remove Final Drive Planetary - Disassemble Duo-Cone Conventional Seals - Install Final Drive Planetary - Assemble Final Drive Planetary - Install Belt - Install |
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