PRODUCT SUPPORT PROGRAM FOR TROUBLESHOOTING EXCESSIVE WATER IN THE TANDEM OIL ON CERTAIN 140M AND 160M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR TROUBLESHOOTING EXCESSIVE WATER IN THE TANDEM OIL ON CERTAIN 140M AND 160M MOTOR GRADERS

Usage:

REBE6336-00

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28Jul2010

U-278

A-213

D-238

O-241

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR TROUBLESHOOTING EXCESSIVE WATER IN THE TANDEM OIL ON CERTAIN 140M AND 160M MOTOR GRADERS
4062 4064		PS51870

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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 "PS51870" 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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TERMINATION DATE

31Jul2012

PROBLEM

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Tandem oil SOS results may indicate excessive water content on certain 140M AND 160M Motor Graders. Excess water in the tandem oil will prevent SOS particle count monitoring. SOS results reporting trace or positive water results are acceptable. Reports indicating excessive water or 1% or more require troubleshooting.

AFFECTED PRODUCT

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Model	Identification Number
140M	B9D00125-02268, 2272-2277, 2279, 2283-2298 B9G00100-00251, 1001-1008 B9M00125-00934 D9G00100-00208, 1001-1011
160M	B9E00115-00405 B9L00115-00120, 150-481 B9T00100-00160 D9T00100-00130

PARTS NEEDED

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Qty	Part Number	Description
2	1U9891	ADDITIVE-OIL - NOT FOR EAME USE
4	3D2981	GASKET
2	4H6112	BREATHER AS
2	6B5072	BUSHING-REDUCING
2	7H3171	PLUG-PIPE
8	8T4223	WASHER-HARD
2	0026453	ELBOW-PIPE
2	1854771	ADDITIVE-OIL - FOR EAME USE ONLY
8	3118290	BOLT-HEX HEAD
1	BULKOIL	TDTO Oil -- 152 Liters (40 Gal)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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 attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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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 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Water entry can occur at several locations around the tandem and the ability for water to enter the tandem is dependent upon the operating environment. Investigation will include the operating conditions, including tandem submersion in ditches, etc., environment including heavy rains, high humidity, and temperature swings. Action should be taken to troubleshoot the tandem only after receiving an SOS report indicating excessive water or 1% or greater water content. Quantification of the water or moisture content with SOS samples is necessary to determine if troubleshooting is necessary. Milky appearance on the tandem walls or frost on the tandem walls above the oil level is not an indication of a problem. This is a natural occurrence and without sufficient heat in the tandem to burn this off as in an engine or transmission, it will be there and continue to accumulate until the next oil change.

Troubleshooting After Receiving A SOS Report Of Excess Water Or Greater Than 1%:
1. Direct pressure wash spray on any of the inspection covers, seals, or breathers can inject water and damage the parts. Communicate the sensitivity of these areas to pressure washing.
2. Water entry may occur at the brake manifold or Tee at the brake line junction on the tandem or at the brake line clip bolts on top of the tandem. Remove the attachment bolts, clean the threads, apply Loctite to the threads, and reinstall the bolts.
3. Material buildup around the breathers may funnel water into the breather. Do not clean the area around the breather with a pressure washer as this will cause water ingress. Clean the area around the breathers with a long screwdriver or hooked instrument when dragging the obstructions clear of the breathers.
4. Insure that the chain cover gaskets are intact and that the cover bolts are properly tightened. If cover bolts are removed, clean the threads and apply Loctite before reinstallation.
Verify that all leak paths were eliminated by performing the following air leak test.

AIR LEAK TEST
1.) INSTALL T-VALVE INTO BREATHER HOLE AND TIGHTEN TO THE PROPER TORQUE
2.) INSERT REGULATED AIR LINE ONTO T-VALVE
3.) HOOK UP SHOP AIR LINE AND APPLY UP TO A MAXIMUM OF 15 PSI (Do not exceed 15 PSI)
4.) SPRAY SOAPY WATER AROUND ALL SEAL AREAS AND CHECK FOR LEAKS
(I.E. FUNNEL SEALS, DUO CONE SEALS, FINAL DRIVE SQUARE AND WELD AT
THE BOTTOM OF TANDEM)
5.) REMOVE SHOP AIR LINE. THIS WILL ALLOW THE AIR TO RELEASE
6.) REMOVE REGULATED AIR LINE AND T-VALVE
7.) INSTALL BREATHER AND TIGHTEN TO THE PROPER TORQUE

If top chain cover gasket is leaking in the center of the side of the gasket or cover, rework the tandem top plate and cover to allow installation of 311-8290 Bolt and 8T-4223 Washer.
1. Drill two 14 C diameter clearance holes on the four 248-6201 Top Chain Cover Plates using the hole center dimensions of the image below to locate the machining.
2. Use the modified cover plate to locate the drilling for the tandem.
3. At each of the 4 top chain cover plate locations, drill and tap two M12 x 1.75 6H holes into the tandem top plate using the modified cover plates to locate the machining.
4. Remove chips and shavings from the tandem. Replace covers and install 6 bolts and washers per cover.

Image1.1.1

If after testing no leaks are found, the tandem breather may be relocated to the inside rear chain cover. Please note that units that operate with an increased oil level for improved brake cooling will burp oil out of the breather if it is relocated to the new position. To relocate the breather, remove the inside rear inspection cover and drill a diameter 18 hole in the center of the chain cover plate. Tap the hole with a 1/2-14 NPTF thread. Install the elbow-pipe, bushing-reducing, and breather as from the parts list. Remove the former breather from on top of the tandem and seal the port with the plug-pipe from the parts list.

Please note that the tandems are unfiltered compartment and as such the iron generated by the chains, the sprockets, the bearings, and the brakes will continue throughout the oil change interval and that means steadily increasing iron levels. You may replace the 6E-5047 Drain Plugs with 304-8032 Magnetic Drain Plugs which will help capture the iron in the tandem so it is more easily removed from the tandems at oil change intervals. NOTE: The 304-8032 Magnetic Drain Plugs are not to be claimed under this program.