PRODUCT SUPPORT PROGRAM FOR REBUILDING THE TRANSMISSION AND TORSIONAL COUPLER ON CERTAIN 16M MOTOR GRADERS
Usage:
REBE5524-04
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| 15Feb2010 |
| (Revised 18Jan2011) |
U-60
A-48
D-54
O-58
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| Before/After | PRODUCT SUPPORT PROGRAM FOR REBUILDING THE TRANSMISSION AND TORSIONAL COUPLER ON CERTAIN 16M MOTOR GRADERS |
|
| 3002 3030 3159 3176 3279 3252 | PS43040 |
|
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| NOTE: | This Program must 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 "PS43040" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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 15Feb2010 (Revised 04Jan2011) Service Letter. A change was made to the mounting bolt part number in the Rework Procedure. |
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TERMINATION DATE |
| 29Feb2012 |
PROBLEM
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| The existing transmission and torsional coupler can fail on certain 16M Motor Graders due to torsional resonance torque spikes caused by lugging the machine below low idle under load and torque spikes caused by certain heavily loaded transmission shifts. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| 16M | B9H00100-00110, 113-115, 117-118, 120, 122-131, 133-141, 143-150, 152-158, 161-185, 187-217, 219-246, 248-294, 296-299, 303, 339, 362, 707-715 |
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| *******Group 2******* | |
| 16M | B9H00111-00112, 116, 119, 121, 132, 142, 151, 159-160, 186, 218, 247, 295, 300-302, 304-338, 340-361, 363-706 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 1T0043 | BEARING-BALL (USE AS REQUIRED) |
| 1 | 1U8846 | SEALANT-GASKET |
| 1 | 2H6489 | RACE-BRG OUTER (USE AS REQUIRED) |
| 1 | 2H6490 | BEARING-INNER (USE AS REQUIRED) |
| 1 | 2K8199 | SEAL-O RING |
| 1 | 2P1692 | SEAL-O RING |
| 1 | 2S3029 | BEARING-BALL (USE AS REQUIRED) |
| 1 | 3E6785 | SEAL-O-RING |
| 1 | 3J1907 | SEAL-O-RING |
| 1 | 3K0360 | SEAL-O-RING |
| 1 | 3K0715 | SEAL-O RING |
| 1 | 3T4377 | SEAL-RING |
| 1 | 4F7952 | SEAL-O RING |
| 1 | 4J0522 | SEAL-O-RING |
| 1 | 4J0524 | SEAL-O-RING |
| 2 | 4J8996 | SEAL-O-RING |
| 1 | 5F3092 | SEAL-O-RING |
| 12 | 5J4715 | WASHER-HARD |
| 2 | 5P2304 | RACE&ROLLER AS (USE AS REQUIRED) |
| 8 | 5P3114 | SEAL-O RING |
| 4 | 5P3863 | SEAL-O-RING |
| 1 | 5P4892 | SEAL-O-RING |
| 2 | 5P7815 | SEAL-O-RING |
| 8 | 5P8247 | WASHER-HARD (After Failure Only) |
| 1 | 6B5154 | BEARING-INNER (USE AS REQUIRED) |
| 8 | 6D7889 | SEAL-O-RING |
| 1 | 6F6672 | SEAL-O RING |
| 24 | 6I8911 | DISC - FRICTION (USE AS REQUIRED) |
| 28 | 6I8912 | DISC - FRICTION (USE AS REQUIRED) |
| 1 | 6K4718 | BEARING (USE AS REQUIRED) |
| 2 | 6V5759 | SEAL-O-RING |
| 12 | 7G4822 | RING-SEAL |
| 3 | 7T4897 | DISC-THRUST |
| 3 | 8E1263 | BEARING-RLR AS (USE AS REQUIRED) |
| 4 | 8E5157 | RACE-BRG OUTER (USE AS REQUIRED) |
| 2 | 8E6558 | RACE-BRG-INNER (USE AS REQUIRED) |
| 14 | 8E8319 | DISC-THRUST |
| 16 | 8F3469 | SEAL-O RING |
| 1 | 8M4992 | SEAL-O RING |
| 3 | 9F8477 | RING-METAL SEAL |
| 2 | 9W2029 | RACE-THRUST (USE AS REQUIRED) |
| 1 | 9W6465 | RETAINER-BEARING (USE AS REQUIRED) |
| 8 | 9X2053 | BOLT-SELF (After Failure Only) |
| 1 | 9X4609 | SEAL- O RING |
| 1 | 1121574 | SEAL-O-RING |
| 5 | 1171385 | SEAL-O-RING |
| 1 | 1334292 | SEAL-LIP TYPE |
| 4 | 1408010 | BRG RACE/RLR AS. (USE AS REQUIRED) |
| 3 | 1458039 | LOCK |
| 7 | 1618313 | RING-SEAL (EXT) |
| 8 | 1650488 | RING-SEAL |
| 12 | 1653929 | BOLT-HEX HEAD |
| 1 | 1719375 | SEAL-O RING |
| 1 | 1880633 | SEAL-BRAKE |
| 12 | 2446849 | SPRING (After Failure Only) |
| 8 | 2446850 | SPRING (After Failure Only) |
| 4 | 2446851 | SPRING (After Failure Only) |
| 2 | 2468749 | PISTON |
| 2 | 2468774 | DISC-THRUST |
| 1 | 2468777 | SEAL-BRAKE |
| 8 | 2468779 | DISC-FRICTION (USE AS REQUIRED) |
| 1 | 2468797 | SEAL-PISTON |
| 1 | 2500951 | RACE-OUTER (USE AS REQUIRED) |
| 1 | 2500952 | BEARING-RLR AS (USE AS REQUIRED) |
| 1 | 2500953 | RACE-OUTER (USE AS REQUIRED) |
| 1 | 2511545 | RACE-INNER (USE AS REQUIRED) |
| 1 | 2688794 | COUPLING AS. (After Failure Only) |
| 1 | 3074611 | SHAFT AS. |
| 1 | 3342679 | SPRING |
| 1 | 3342680 | SPRING |
| 1 | TRANS_OIL | BULK TRANS OIL [91 LITERS (24 GALS)] |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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 | 1T0043 | BEARING-BALL (USE AS REQUIRED) |
| 1 | 1U8846 | SEALANT-GASKET |
| 1 | 2H6489 | RACE-BRG OUTER (USE AS REQUIRED) |
| 1 | 2H6490 | BEARING-INNER (USE AS REQUIRED) |
| 1 | 2K8199 | SEAL-O RING |
| 1 | 2P1692 | SEAL-O RING |
| 1 | 2S3029 | BEARING-BALL (USE AS REQUIRED) |
| 1 | 3E6785 | SEAL-O-RING |
| 1 | 3J1907 | SEAL-O-RING |
| 1 | 3K0360 | SEAL-O-RING |
| 1 | 3K0715 | SEAL-O RING |
| 1 | 3T4377 | SEAL-RING |
| 1 | 4F7952 | SEAL-O RING |
| 1 | 4J0522 | SEAL-O-RING |
| 1 | 4J0524 | SEAL-O-RING |
| 2 | 4J8996 | SEAL-O-RING |
| 1 | 5F3092 | SEAL-O-RING |
| 12 | 5J4715 | WASHER-HARD |
| 2 | 5P2304 | RACE&ROLLER AS (USE AS REQUIRED) |
| 8 | 5P3114 | SEAL-O RING |
| 4 | 5P3863 | SEAL-O-RING |
| 1 | 5P4892 | SEAL-O-RING |
| 2 | 5P7815 | SEAL-O-RING |
| 8 | 5P8247 | WASHER-HARD (After Failure Only) |
| 1 | 6B5154 | BEARING-INNER (USE AS REQUIRED) |
| 8 | 6D7889 | SEAL-O-RING |
| 1 | 6F6672 | SEAL-O RING |
| 24 | 6I8911 | DISC - FRICTION (USE AS REQUIRED) |
| 28 | 6I8912 | DISC - FRICTION (USE AS REQUIRED) |
| 1 | 6K4718 | BEARING (USE AS REQUIRED) |
| 2 | 6V5759 | SEAL-O-RING |
| 12 | 7G4822 | RING-SEAL |
| 3 | 7T4897 | DISC-THRUST |
| 3 | 8E1263 | BEARING-RLR AS (USE AS REQUIRED) |
| 4 | 8E5157 | RACE-BRG OUTER (USE AS REQUIRED) |
| 2 | 8E6558 | RACE-BRG-INNER (USE AS REQUIRED) |
| 14 | 8E8319 | DISC-THRUST |
| 16 | 8F3469 | SEAL-O RING |
| 1 | 8M4992 | SEAL-O RING |
| 3 | 9F8477 | RING-METAL SEAL |
| 2 | 9W2029 | RACE-THRUST (USE AS REQUIRED) |
| 1 | 9W6465 | RETAINER-BEARING (USE AS REQUIRED) |
| 8 | 9X2053 | BOLT-SELF (After Failure Only) |
| 1 | 9X4609 | SEAL- O RING |
| 1 | 1121574 | SEAL-O-RING |
| 5 | 1171385 | SEAL-O-RING |
| 1 | 1334292 | SEAL-LIP TYPE |
| 4 | 1408010 | BRG RACE/RLR AS. (USE AS REQUIRED) |
| 3 | 1458039 | LOCK |
| 7 | 1618313 | RING-SEAL (EXT) |
| 8 | 1650488 | RING-SEAL |
| 12 | 1653929 | BOLT-HEX HEAD |
| 1 | 1719375 | SEAL-O RING |
| 1 | 1880633 | SEAL-BRAKE |
| 12 | 2446849 | SPRING (After Failure Only) |
| 8 | 2446850 | SPRING (After Failure Only) |
| 4 | 2446851 | SPRING (After Failure Only) |
| 2 | 2468774 | DISC-THRUST |
| 1 | 2468777 | SEAL-BRAKE |
| 8 | 2468779 | DISC-FRICTION (USE AS REQUIRED) |
| 1 | 2468797 | SEAL-PISTON |
| 1 | 2500951 | RACE-OUTER (USE AS REQUIRED) |
| 1 | 2500952 | BEARING-RLR AS (USE AS REQUIRED) |
| 1 | 2500953 | RACE-OUTER (USE AS REQUIRED) |
| 1 | 2511545 | RACE-INNER (USE AS REQUIRED) |
| 1 | 2688794 | COUPLING AS. (After Failure Only) |
| 1 | 3342679 | SPRING |
| 1 | 3342680 | SPRING |
| 1 | TRANS_OIL | BULK TRANS OIL [91 LITERS (24 GALS)] |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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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| If the machine has lost use of multiple forward and reverse gears, remove the magnetic transmission screens. Check the screens for metal debris such as broken bolts and washers. Check the magnetic screen prior to performing any of the diagnostic tests for the power train that are described in the Testing and Adjusting, RENR8482. Some of the diagnostic tests for the power train require the engine to be run in order to complete the tests. Running the engine may cause further damage to the rear gear group. Damage to the rear gear group of the engine could result if the bolts that hold the torsional coupler to the engine flywheel have failed. The transmission pump supplies lubrication to the gears and the bearings within the flywheel housing. The transmission pump will not be operational if the bolted joint for the torsional coupling has failed. If the machine has less than 1,000 hours, or PI10780 was completed before there were 1,000 hours on the machine, there has not been enough hour accumulation to have damage caused by torsional resonance torque spikes. Ensure that service letter program PI10780 has been completed. PI10780 addresses the root cause of the issue covered in this program and prevents the machine from seeing the damaging torque spikes during machine application and no further action is needed. If the machine has more than 1,000 hours and PI10780 was completed after the machine had 1,000 hours, perform the following procedures listed in Rework Procedure. |
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SERVICE CLAIM ALLOWANCES
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