PRODUCT SUPPORT PROGRAM FOR REPLACING THE O-RING SEAL AND TEFLON SEAL RING ON CERTAIN 14M AND 16M MOTOR GRADER TRANSMISSION CLUTCH PISTONS AND SHAFTS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE O-RING SEAL AND TEFLON SEAL RING ON CERTAIN 14M AND 16M MOTOR GRADER TRANSMISSION CLUTCH PISTONS AND SHAFTS

Usage:

TEBE2870-01

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10Apr2015

(Revised 22Jun2016)

B090
B150
B152
B153
B253
B270
B290
B299
B420
D070
D260
D263
D390
D392
D420
D426
D600
E070
E07A
E130
E140
E14G
E250
E300
E400
E401
E480
E481
E490
E500
H070
H072
H160
H200
H270
H330
H342
H345
H370
H371
H430
H510
J040
J09R
J0AA
J122
J370
J490
J540
J570
K02A
K02C
K030
K031
K040
K042
K090
K113
K314
K319
K363
K36C
K380
K430
K590
K600
K632
K645
K646
K680
L030
L100
L240
L390
M030
M450
M610
M620
M623
N020
N030
N037
N050
N053
N055
N057
N061
N065
N067
N070
N071
N074
N083
N085
N090
N126
N140
N143
N170
N171
N172
N173
N174
N175
N176
N178
N182
N184
N187
N188
N18C
N191
NONE
P050
P05Z
P280
P282
P285
Q301
Q302
Q303
Q305
Q550
Q630
Q631
Q632
Q633
Q635
Q636
Q637
Q639
R050
R080
R120
R12Z
R160
R180
R350
R400
R405
R461
T030
T032
T035
T038
T080
T088
T089
T120
T168
T210
U060
U066
U067
U069
U071
V21A
V255
V262
V27E
V351
V363
X156
X167
X168
X260
X286
X460
Y496
Y500
Z800

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE O-RING SEAL AND TEFLON SEAL RING ON CERTAIN 14M AND 16M MOTOR GRADER TRANSMISSION CLUTCH PISTONS AND SHAFTS
3155 3063 3170		PS52908

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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 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 "PS52908" 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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NOTE:	This Revised Service Letter replaces the 10Apr2015 Service Letter. Changes have been made to the Termination Date, Affected Product, Service Claim Allowances, and Rework Procedure.

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TERMINATION DATE

31Dec2017

PROBLEM

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Premature clutch wear is predominately experienced in clutches 1, 2, and 3 under 1500 hours. Assembly damage to the piston seals can result in premature clutch wear. On clutch number one and clutch number two the wear is occurring to part number 6I-8911 Friction Discs (1). On clutch number three the wear is occurring to part number
6I-8912 Friction Discs (2). Refer to Table 1 in the Rework Instructions for information regarding the above part numbers.

Note: Improper seal installation can result in premature seal failure and clutch wear. Proper seal installation procedures can eliminate the risk of seal damage during installation. Reference the steps outlined in the rework instructions to ensure proper seating and installation of the piston seals and shaft seals.

AFFECTED PRODUCT

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Model	Identification Number
14M	R9J00899-00900, 902, 904-915, 919-1149, 1151-1220, 1222-1229, 1231-1236, 1239-1240, 1242-1250, 1252-1255, 1257-1267, 1269-1273, 1276-1285, 1287-1292, 1294-1299, 1301-1329, 1331-1349, 1351-1363, 1365-1382, 1384-1463, 1465-1468, 1470, 1472, 1475, 1477, 1487, 1489-1495, 1497-1498, 1500-1501, 1503, 1505-1506, 1508, 1520, 1524-1525, 1527-1529, 1531, 1536, 1542, 1547, 1549-1550, 1552-1553, 1557-1562, 1564, 1567, 1569-1575, 1577, 1601, 1606, 1610, 1614, 1621, 1630, 1633, 1637
16M	B9H00822 R9H00808-00811, 813-925, 927-977, 979-982, 984-985, 987

PARTS NEEDED

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Qty	Part Number	Description
1	1H6227	SEAL-O RING
1	1P3705	SEAL-RECTANGULAR
1	1S9799	SEAL-O RING
1	3E6785	SEAL-O-RING
1	3K0715	SEAL-O RING
1	4J0520	SEAL-O-RING
7	4J0522	SEAL-O-RING
2	4J0524	SEAL-O-RING
1	4J0527	SEAL-O-RING
1	4J5267	SEAL-O-RING
1	4J5477	SEAL-O-RING-ORFS
6	5K9090	SEAL-O-RING-ORFS
8	6V8397	SEAL-O-RING-ORFS
8	6V8398	SEAL-O-RING-ORFS
3	6V8400	SEAL-O-RING-ORFS
7	6V9746	SEAL-O-RING-ORFS
4	7J9108	SEAL-O-RING-ORFS
1	9X7380	SEAL-O-RING
1	9X7381	SEAL-O-RING
1	9Y8386	GASKET
2	1654854	SEAL-O-RING
8	2907514	BOLT-HEX HEAD
1	3283655	ELEMENT AS-XMSN
1	3491435	KIT-DT GASKET
1	4151704	SEAL-O-RING
1	4151706	RING-SEAL
1	OIL_BULK	TRANS OIL - 100L (26.4 Gal) See OMM
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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 Service Manual if/as necessary and see the attached Rework Procedure.

Reference: Service Magazine, SEPD1569, "New Seal Rings and Pistons Are Now Used in the Transmission Clutches for Certain 14M and 16M Motor Graders"

Reference: Operational and Maintenance Manual,SEBU6250, "Transmission/Drive Train Oil"

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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%
0-3000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 118.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Additionally, each dealership will be able to claim $175 (one time only) towards the purchase of the Installation Tool (426-2786) to be used for installing the Clutch Piston Seals, as a miscellaneous item.

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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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1. Identify the clutch that has experienced a friction disc failure and or piston seal failure. Refer to below illustrations for various examples.

Image1.1.1

Image1.1.2

Image1.1.3

2. Inspect All clutch pistons and seals for any twisting or rolling of the seal. Refer to the below illustrations for two examples.

Image1.2.1

Replace Teflon Piston Seals Using the Following Procedure

Note: The following procedure is applicable to transmission clutches built with the Teflon seal rings on the pistons and shafts. If the Teflon seal rings are not currently installed on the pistons then, refer to Service Magazine, SEPD1569, "New Seal Rings and Pistons are Now Used in the Transmission Clutches for Certain 14M and 16M Motor Graders" to update the needed transmission components to allow use of
the improved seals.

Note: The assembler must wear gloves to prevent injury while performing this rework.

1. Remove all piston seals and shaft seals.

2. Lubricate the shaft and shaft seal groove with transmission differential oil as specified in the Operation and Maintenance Manual for your machine.

Image1.5.1

Image1.5.2

3. Lubricate O-ring seal (6) and install O-ring seal (6) into the shaft groove by hand.

4. Lubricate Teflon seal ring (5) using transmission differential oil as specified in the Operation and Maintenance Manual for your machine.

5. Install Teflon seal ring (5) into the groove 50% of the way around the shaft by hand. Finish the installation into the seal groove using the proper straight, smooth tipped installation tool seal pick (AA). Refer to Illustration 3.

Note: Do not overstretch Teflon seal ring (5).

Image1.8.1

6. Carefully install the pick between Teflon seal ring (5) and the shaft. Gently guide the pick around the shaft to engage Teflon seal ring (5) properly into the groove as shown above.

7. Apply pressure with thumb around the shaft groove. This procedure ensures that Teflon seal ring (5) is properly seated with no rolling or flaring of Teflon seal ring (5).

8. Lubricate the seal groove and piston with transmission/differential oil as specified in the Operation and Maintenance Manual for your machine.

Image1.11.1

9. Install O-ring seal (3) in the seal groove by hand.

Image1.12.1

10. Place 426-2786 seal installer (A) on the top of the piston. Insure that the seal installer (A) is seated.

Image1.13.1

11. Lubricate Teflon seal ring (4) using transmission/differential oil as specified in the Operation and Maintenance Manual for your machine.

12. Install the Teflon seal ring onto the seal installer (A), then cupping your hands around the guide, slide the seal down the guide until the seal slips into the ring groove. Refer to illustration for proper hand placement.

Image1.15.1

13. Spin the piston several times while applying pressure with thumb to Teflon seal ring (4). This procedure ensures a proper seat with no rolling or flaring of the Teflon seal ring.

Image1.16.1

Image1.16.2

14. Visually inspect Teflon seal ring (4) to ensure that Teflon seal ring (4) is seated squarely in the groove of the piston. Refer to Illustration 9. If the seal is canted in the groove, as shown in Illustration 10, the seal may be damaged during
installation into the cylinder. Repeat Teflon seal ring assembly procedure until the Teflon seal ring is squarely seated.

15. Apply transmission/differential oil as specified in the Operation and Maintenance Manual to the following:
? Shaft-side piston pocket OD
? Shaft seal and lands ID
? The piston

16. Lower the piston into the cylinder using your hands only.

Image1.19.1

17. Seat the piston into the bottom of the cylinder by pressing indicated-areas. Press the three areas in a circular continuous (B), (C) and (D) three point pattern. Perform this action until the piston is fully seated.

18. After completing the assembly of the shaft, use a soft tipped blow gun to pressure test the assembly. Apply air pressure of less than 150 PSI to the clutch pressure ports on the end of the shaft.

19. If leakage is detected, disassemble the clutch, remove the piston, and inspect the clutch and piston for the cause of the air leak. Reassemble the piston and clutch according to the above instructions and retest.