PRODUCT SUPPORT PROGRAM FOR REPAIRING AND REPLACING THE BRAKE FRICTION DISCS, SEPARATOR PLATES, LOW BIAS VALVES, AND MACHINING THE COVERS ON CERTAIN 160M MOTOR GRADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING AND REPLACING THE BRAKE FRICTION DISCS, SEPARATOR PLATES, LOW BIAS VALVES, AND MACHINING THE COVERS ON CERTAIN 160M MOTOR GRADERS

Usage:

TEBE0296-00

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27Aug2013

Q631

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPAIRING AND REPLACING THE BRAKE FRICTION DISCS, SEPARATOR PLATES, LOW BIAS VALVES, AND MACHINING THE COVERS ON CERTAIN 160M MOTOR GRADERS
4296		PS90319

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NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90319" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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

31Aug2014

PROBLEM

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The Service Brake Control Valve has a high bias to the left hand tandem
on certain 160M Motor Graders. This can be a contributing factor to premature brake failures when brakes are partially applied to modulate speed.
The failures are typically found in applications while roading in hilly terrain.
The result of the failure is service brake friction discs overheat,
warp, or fracture. Overheating of the brake discs can be detected by
the smell of burnt tandem oil, complaints of noisy brakes, grabbing
brakes, or locked up brakes.

AFFECTED PRODUCT

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Model	Identification Number
160M	B9E00218, 223, 285, 300, 302-304, 308, 315, 338

PARTS NEEDED

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Qty	Part Number	Description
8	3K0360	SEAL-O-RING
10	6V8398	SEAL-O-RING-ORFS
4	2204335	SEAL-BRAKE
4	2204336	SEAL-BRAKE
28	2849557	PLATE
24	3510925	DISC-FRICTION
1	3557411	VALVE GP-BRAKE-A
1	BULK_OIL	Hydraulic Oil (19 Liters) or 5 gallons
1	OIL_BULK	Tandem oil - As required
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 following instructions and images to replace the existing
brake valve with the low bias brake valve.
Refer to the appropriate Service Manuals if/as necessary.
Reference: Operation and Maintenance Manual, "Lubricant Viscosities"
Reference: Operation and Maintenance Manual, "Capacities (Refill)"
Reference: Testing and Adjusting, "Brake System Air - Purge"
Reference:
160M - RENR9727 Disassembly and Assembly - "Control Valve (Brake)"
OMM - SEBU7990 ? "Operation"
Note: Before applying this Service Letter, inspect brake friction discs
and plates according to reuse guidelines.
Note: Ensure correct tandem oil fluid is being used per OMM for your
area and operating techniques for hilly applications.
Note: Ensure correct Hydraulic fluid is being used per OMM for your
area.
Note: Block wheels and tag out machine before performing this Service
Letter.

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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%
5001-9000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 33.0-hour job
Note: This is a 3.0-hour job for Low Bias valve Note: 30 Hours allowed for brake disc. Note: Bulk Hydraulic and Tandem oil are only offered for machines up to 5,000 hours

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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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Inspect the 284-9557 Service Brake Separator Plates and 259-6836 Friction Discs for warping or excessive heat discoloration. Refer to the Disassembly and Assembly Manual for instructions for removing the wheel group. See attached salvage and replacement guidelines. If separator plate or friction disc replacement is necessary, replace the friction disc with 351-0925 Disc-Friction or the plate with the 284-9557 Plate. Review operating environment for implementation of lower viscosity oil, which meets the current temperature matrix requirements, and applicability of overfill recommendations.

Disc Replacement Guidelines
1. Measure the friction disk thickness with a micrometer as shown in Image 3.1.1. Replace friction disc if it has more than 50% wear indicated by a thickness of 3.45 mm (0.136 in) or less.
2. Measure lining wear on both sides of the disc. The lining wear should be approximately even side-to-side. The lining in one side of the disc should not be less than 1/2 the thickness of the other side. Lining wear that exceeds the groove depth is not permitted on either side at any location.
3. Do not reuse a disc if more than 10% of the friction material has "flaked" off or if the friction material appears to be very easily chipped when applying light prying pressure.
4. "Warped", "glazed", and/or "burnt" discs that exhibit signs of excessive temperature should be replaced in all instances. Do not reuse a plate that is warped. A plate is considered warped if a 0.25 mm (0.010 in) feeler gauge will fit between the plate and a flat surface.
5. Inspect the disc teeth. Do not reuse discs with broken teeth.

Image1.1.1

Low Bias Valve Replacement
1. Depress brake pedal repeatedly until the brake accumulator is drained of pressurized oil.
2. Install a vacuum cap tool onto the hydraulic tank and pressurize (refer to Disassembly and Assembly "Control Valve (Brake)").
Note: Until the 14M and 16M manual is updated, refer to the 140M and 160M D&A.

Image1.2.1

3. Remove the covers directly in front of the cab.
4. Remove and cap any hoses in the way of the Brake Control Valve, if needed.
5. Remove and cover or cap all six tubes going to the 308-9523 Brake Control Valve.
a. Note: You can use small cable straps around the steel Tubes behind the nut to keep them from sliding under the cab if you are not using caps.

Image1.3.1

6. Remove the two brake control valve mounting bolts.
7. Remove the brake control valve and place the valve into a vice.
8. Remove all fittings and connectors from the valve and replace the 3K-0360 Seals on the fittings. Remove the 6V-8398 Seals at this time.
9. Install all fittings and connectors to the 355-7411 Brake Valve but do not tighten at this time.
10. Install the 355-7411 Brake Valve on the machine using the two original mounting bolts.
11. Assemble the six tubes, from Step #5, back to the loose fittings and connections. Tighten the fittings, connections, and Tubes at this time.
a. Note: Remove any cable straps that may have been added from Step #5
12. Remove Tooling (A).
13. Check hydraulic oil level, fill as needed.
14. Start machine and let engine and hydraulic oil stabilize.
15. Check the brake valve for leaks.
16. Depress brake pedal several times to verify the brake accumulator is charged and the brake pedal is responding to movement.
17. Shut off machine.
18. Bleed brakes according to Testing and Adjusting "Brake System Air ? Purge"
19. Reinstall the cover(s) that were removed in Step #3.