PRODUCT SUPPORT PROGRAM FOR REWORKING THE DRIVE MOTORS ON CERTAIN 257D, 277D, 287D, 297D, 297D XHP MULTI-TERRAIN LOADERS AND 259D, 279D, 289D, 299D, 299D XHP COMPACT TRACK LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE DRIVE MOTORS ON CERTAIN 257D, 277D, 287D, 297D, 297D XHP MULTI-TERRAIN LOADERS AND 259D, 279D, 289D, 299D, 299D XHP COMPACT TRACK LOADERS

Usage:

TEBE2713-01

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14Apr2015

(Revised 25Jan2016)

U-180

A-122

D-136

O-137

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE DRIVE MOTORS ON CERTAIN 257D, 277D, 287D, 297D, 297D XHP MULTI-TERRAIN LOADERS AND 259D, 279D, 289D, 299D, 299D XHP COMPACT TRACK LOADERS
3154		PS44709

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS44709" 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 14Apr2015 Service Letter. Changes have been made to the Affected Product and Rework Procedure. New verbiage has been added to the end of Step 4 in 'All Groups':
NOTE: IT IS CRITICAL THAT THE M8 ALL THREAD ROD IS USED FOR THIS OPERATION. FAILURE TO USE THE PROPER TOOLING WILL LIKELY CAUSE CATASTROPHIC DRIVE MOTOR FAILURE AFTER THE REPAIR IS COMPLETE. All failed drive motors are being returned and inspected. If a drive motor is found to have failed as a result of not following this procedure, the warranty claim will be debited.

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TERMINATION DATE

30Apr2017

PROBLEM

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The existing drive motors can leak on certain 257D, 277D, 287D, 297D, 297D XHP Multi-Terrain Loaders and 259D, 279D, 289D, 299D, 299D XHP Compact Track Loaders. If the existing drive motor two speed O-ring erodes it will result in hydraulic fluid leaking from the interface between the drive motor halves.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
257D	EML00121 EZW00210, 213, 215, 217, 219, 221, 223, 228-231, 233-236, 238-246, 248-252, 256-257, 259-261, 267, 270-273, 276-280, 282-287, 291-293, 295-315, 317, 320-323, 333, 335-343, 345-346, 348-352, 355, 358-363, 368-369, 371, 373-383, 386-387, 389-391, 393, 395, 401-402, 405-408, 411-416, 423-428, 432, 436-444, 446-455, 462-463, 465-466, 468, 473-479, 481-482, 484, 487-488, 491-499, 501-504, 516-541, 545-548, 553-560, 563, 567, 570-575, 578, 580, 583, 585-587, 589-592, 596, 600, 602-612, 614-616, 618-621, 623, 625-626, 628-629, 631-634, 636-638, 640-642, 645, 649, 654, 658-659, 664-678, 682-693, 698-700, 703, 705-708, 710-716, 720, 722-726, 730-731, 735, 740-741, 746-747, 751, 753, 755-762, 764-767, 769-771, 773-777, 780-782, 784-786, 788-789, 793-800, 803-827, 829-832, 835, 837-840, 842, 845-847, 849-852, 854-858, 860, 862-867, 870-891, 895, 897, 901, 903-905, 907-920, 922-927, 929, 931-932, 936-947, 953, 955, 960-966, 968-970, 972-976, 978, 980-981, 985-987, 989, 991-994, 996-1000, 1004-1028 FMR00125-00146, 148-155, 157-174, 176-183, 185-256, 259-260, 262-277, 279, 281, 283
259D	FTK00135, 235-661 FTL00061, 115-117, 215-2259, 2261-4081 GTK00130-00147

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*****Group 2*****
279D	GTL00115, 215-2089 PPT00270, 274-275 RCX00175, 275-476
289D	A9Z00200, 300-529 TAW00125-00126, 225-2847 WCT00289
299D	GTC00225, 300-1847
299D XHP	JST00236-01236

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*****Group 3*****
277D	FMT00210-00532 MLT00160-00161 NTL00165, 265-315
287D	HMT00120, 220-224, 227-582 STK00180, 183 TLK00185-00229
297D	BE700200-00265
297D XHP	HP700210-00240

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	6V8397	SEAL-O-RING-ORFS
2	6V8398	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
8	7K1181	STRAP-CABLE
4	2042281	STRAP-CABLE
2	4557971	KIT-SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% 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*****
4	6V8397	SEAL-O-RING-ORFS
2	6V8398	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
8	7K1181	STRAP-CABLE
4	2042281	STRAP-CABLE
2	4557971	KIT-SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 14% 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*****
4	6V8397	SEAL-O-RING-ORFS
2	6V8398	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
8	7K1181	STRAP-CABLE
4	2042281	STRAP-CABLE
2	4557971	KIT-SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 14% 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%
*****Group 1*****
0-1500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.0-hour job for Group 1
Note: The 10.0 hour allowance covers repair of both motors using the described method of removing motors from the machine.

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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%
*****Group 2*****
0-1500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 8.0-hour job for Group 2
Note: The 8.0 hour allowance covers repair of both motors using the described method of removing undercarriage from machine and leaving motors in the roller frames.

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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%
*****Group 3*****
0-1500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 10.0-hour job for Group 3
Note: The 10.0 hour allowance covers repair of both motors using the described method of removing motors from the machine.

PARTS DISPOSITION

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

Rework Procedure

FOR GROUPS 1 AND 3:

1. Remove the drive motor from the machine. Refer to UENR3730, Disassembly and Assembly, "Piston Motor (Hydrostatic) - Remove and Install".

2. To prevent contamination, clean dirt from around circumference of motor.

FOR GROUP 2:

1. Remove undercarriage from machine. Refer to UENR3730, Disassembly and Assembly, "Undercarriage - Remove and Install". The track belt can be left on. Leave the motors in the undercarriage in order to perform the remaining rework.

2. Drain the oil from the motor case. Refer to Image1.2.1.

Image1.2.1

3. To prevent contamination, clean dirt from around circumference of motor.

4. Position the undercarriage on its side with motor facing upward.

ALL GROUPS:

1. Remove the STOR plug from the back of the disc brake cover. Refer to Image1.4.1 and 1.4.2.

Image1.4.1

Image1.4.2

2. Remove the eight M10 bolts that hold the motor cover to the main housing of the motor. Refer to Image1.5.1.

Image1.5.1

3. Obtain a M8 all thread rod 150mm (0.49ft) and add a double nut or weld a nut to one end. Refer to Image1.6.1.

4. Install the M8 rod into the open port on the brake cover and thread into the brake piston. The rod will contact the top of the motor shaft and keep it in place. Refer to Image1.6.2.

NOTE: DO NOT USE AN M8 BOLT FOR THIS OPERATION. THE THREADS WILL NOT BE LONG ENOUGH FOR THE COVER TO CLEAR THE TOP OF THE MOTOR SHAFT.

NOTE: IT IS CRITICAL THAT THE M8 ALL THREAD ROD IS USED FOR THIS OPERATION. FAILURE TO USE THE PROPER TOOLING WILL LIKELY CAUSE CATASTROPHIC DRIVE MOTOR FAILURE AFTER THE REPAIR IS COMPLETE. All failed drive motors are being returned and inspected. If a drive motor is found to have failed as a result of not following this procedure, the warranty claim will be debited.

Image1.6.1

Image1.6.2

5. Steady the cover and turn the M8 rod clockwise many turns. Ensure that the cover is completely clear of the motor shaft before lifting the motor cover off the housing. The minimum gap between the cover and the lower motor should be 50mm (2in) before lifting off. Refer to Image1.7.1.

NOTE: FAILURE TO CLEAR THE MOTOR SHAFT WILL CAUSE THE SHAFT TO COME OUT OF POSITION WHEN THE COVER IS REMOVED. If this happens, hydraulic oil has entered and contaminated the gear box. THE GEAR BOX OIL MUST BE CHANGED!

Image1.7.1

No further disassembly of motor is required at this point.

6. With the cover removed, replace small two speed 475-0275 O-rings, large case 8T-6404 O-ring Seal, and install steel insert all supplied in the 455-7971 Seal Kit. Refer to Image 1.8.1.

Image1.8.1

7. On the back side (steel) of the valve plate apply assembly, grease to the lapped surfaces. Refer to Image1.9.1. Install the valve plate onto the motor cover. Position the valve plate with the timing dowel pin. Refer to Image1.9.2. Apply grease to outer diameter of the bearing in order to help it maintain its installed position.

Image1.9.1

Image1.9.2

8. Install two M10 alignment rods on opposing sides of the motor housing.

NOTE: ALIGNMENT RODS ARE ESSENTIAL TO PREVENT DAMAGE TO THE REAR SHAFT SEAL DURING REASSEMBLY.

9. Ensure the following parts are in place and seated properly: steel insert, small O-ring, large O-ring, and alignment dowel pins. Refer to Image1.10.1.

10. Check that the inner bearing race on the motor shaft is in position with flange side down.

11. Perform a final inspection of the flange surface in order to ensure that there is no debris.

Image1.10.1

12. Remove the M8 threaded rod extraction tool from the cover.

13. Line up the motor cover onto the two M10 alignment rods ensuring that the notch in the motor cover lines up over the two speed O-ring and insert. Refer to Image1.11.1.

Image1.11.1

14. Place a feeler gauge on top of the steel insert and hold down while motor cover is being installed. For GROUPS 1 and 3 refer to Image1.12.1. For GROUP 2 refer to Image1.12.2.

Image1.12.1

Image1.12.2

CAUTION!
As the motor cover is lowered, residual oil in the motor housing will travel up the two speed passage and can unknowingly dislodge the steel insert from the counterbore. If the insert leaves its position it will likely get crushed between the top cover and lower motor interface as the bolts are tightened. This will most likely damage the motor resulting in complete motor replacement. Refer to Image1.13.1.

Image1.13.1

15. Lower the cover as level as possible to ensure it is centered up when the motor shaft passes thru the shaft seal. Refer to Image1.14.1.

16. Lower the cover until the top of the shaft contacts the internal splines of the brake coupler.

17. If the motor shaft aligns correctly with the brake coupler splines, the motor cover may lower down all the way until the valve plate contacts the top of the rotating kit. It is likely that the cover will not align immediately. Remove the M10 alignment rods. Holding the weight of the motor cover, gently rotate a few degrees clockwise/counterclockwise until the splines line up. Keeping the cover level will assist the alignment. Refer to Image1.14.2.

NOTE: DO NOT FORCE THE MOTOR COVER DOWN. IF ALIGNMENT IS CORRECT THE COVER WILL LOWER WITH ITS OWN WEIGHT.

Image1.14.1

Image1.14.2

18. With the motor cover lowered, install two of the M10 assembly bolts on opposite side, adjacent to the main work ports.

19. Alternate tightening the two bolts, slowly 1/2 turn at a time. Refer to Image1.15.1. When top cover begins to contact the feeler gauge, remove the gauge and continue tightening the bolts until the cover is mated to the motor housing.

NOTE: DO NOT FORCE THE END COVER DOWN. IF EXCESSIVE TORQUE IS FELT ON THE BOLTS DURING THE DRAW DOWN, THEN SOMETHING IS NOT ALIGNED. Remove the cover with the M8 threaded rod, check the parts, and repeat Steps 4 through 19.

Image1.15.1

20. Install the remaining M10 assembly bolts and tighten all bolts in a crossing pattern to a specified torque of 80 +/- 5 N.m (60 +/- 4 lb ft). Refer to Image1.16.1.

21. Install the brake cover port plug and tighten to a specified torque of 15 +/- 2 N.m (133 +/- 18 lb in). Refer to Image1.16.2.

Image1.16.1

Image1.16.2

22. Check service internal for the gearbox oil, change if required.

FOR GROUPS 1 AND 3:
Install the drive motor on the machine. Refer to UENR3730, Disassembly and Assembly, "Piston Motor (Hydrostatic) - Remove and Install". Replace the O-rings in all hose connections.

FOR GROUP 2:
Install the undercarriage. Refer to UENR3730, Disassembly and Assembly, "Undercarriage - Remove and Install". Replace the O-rings in all hose connections.

Note: If axle end plates were removed, use Loctite on bolts when installing.