PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER ON CERTAIN OEM TRANSMISSIONS AND POWER MODULES USED IN TELEHANDLERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER ON CERTAIN OEM TRANSMISSIONS AND POWER MODULES USED IN TELEHANDLERS

Usage:

REBE6703-00

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18Jul2012

U-382

D-334

O-351

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER ON CERTAIN OEM TRANSMISSIONS AND POWER MODULES USED IN TELEHANDLERS
3101		PS52262

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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 "PS52262" 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

31Jul2014

PROBLEM

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The existing 230-7551 Torque Converter can fail on certain OEM Transmissions and Power Modules used in Telehandlers. If the existing torque converter fails it will cause loss of drive and potential contamination. Installation of the new torque converter will prevent repeat failures.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
TRANS OEM	LKT00504, 40109-40146, 40148-40246, 40248-40277, 40279-40322, 40324-40481, 40483-40524, 40526-40710, 40712-40743, 40745-40780, 40782-40783, 40786, 40788-40803, 40805, 40807-40811, 40813-40846, 40848-40924, 40926-40981, 40983-40985, 40988-40990, 40993, 40996, 40999-41000, 41003-41006, 41017-41024, 41029, 41035-41037, 41039-41057, 41059-41077, 41079-41087, 41089-41114, 41117, 41119-41165, 41167-41192, 41194-41201, 41203-41205, 41213, 41217-41228, 41253-41258, 41262-41263, 41266-41273, 41275-41306, 41308-41309, 41311-41319, 41321-41322, 50109-50159, 50161-50210, 50212-50255, 50258-50299, 50308-50427, 50429-50438, 50441-50531, 50533-50535, 50537, 50540-50607, 50612-50654, 50656-50674, 50676-50730, 50732-50741, 50743-50843, 50849, 50851-50857, 50859-50863, 50868, 50872, 50883-50886, 50888-50920, 50922-50933, 50938-50944, 50946-50950, 50952-50955, 50957-50966, 50968-50975, 50977-50988, 50990, 50993-50995, 50998-50999, 51023, 51029-51032, 51034-51035, 51039-51040, 51043-51044, 51046, 51048, 51059, 51067, 51080, 51086-51117, 51120, 51124-51163, 51165-51224, 51226, 51228-51254, 51256-51269, 51271-51303, 51314-51379, 70888

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*****Group 2*****
PM OEM	MLS00101-00596, 598-603, 605-610, 613-930, 932-937, 941-945, 948-953, 956-996, 998-1001, 1003-1347, 1349-1496, 1498-1686, 1688-1708, 1710-1720, 1722, 1724-1772, 1775-2203, 2205-2322, 2324-2394, 2396-2556, 2558-2560, 2562, 2565-2623, 7531, 7594, 99998

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1G8878	FILTER AS-HYD
8	1076826	BOLT-12 POINT HD
1	1788164	SEAL-OIL
1	2681711	CONVERTER AS.
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.
*****Group 2*****
1	1G8878	FILTER AS-HYD
8	1076826	BOLT-12 POINT HD
1	1788164	SEAL-OIL
1	2681711	CONVERTER AS.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Replace torque converter by following attached rework Procedure and relevant Service Manuals.

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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*****
0-2000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-3000 hrs, 13-24 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 1
An additional 25 hours labor to flush and clean the oil system can be claimed if there was a major failure that sent debris through the system. The filter should be cut open and an SOS sample taken to confirm debris is present. The SOS report should be attached to the warranty claim when filing for the additional labor.

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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*****
0-4000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-5000 hrs, 13-24 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 2
An additional 25 hours labor to flush and clean the oil system can be claimed if there was a major failure that sent debris through the system. The filter should be cut open and an SOS sample taken to confirm debris is present. The SOS report should be attached to the warranty claim when filing for the additional labor.

PARTS DISPOSITION

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

Rework Procedure

Replace the failed 230-7551 Torque Converter using the following procedure for both Group 1 and Group 2.

Refer to the following service manuals as required:
TH220B and TH330B Service Manual_31200262: Power Train Disassembly and Assembly.
TH360B and TH560B Service Manual_31200264: Power Train Disassembly and Assembly.
TH580B Service Manual_31200266: Power Train Disassembly and Assembly.
TH336, TH337, TH406, TH407, TH414, TH514 and TH417 Service Manual_31200370: Transmission.

All of the above Service Manuals are available from the Cat Alliance Group (CAG) web site. A link to this web site is available from the "Additional Service Information" section on the front screen of SIS, under "CAT Branded Telehandlers".

Before carrying out the following procedure, identify the serial number of the transmission installed in the machine in question, and ensure that that transmission serial number is listed under "Affected Product" in this publication.

1. Remove the transmission and torque converter from the machine and then remove the converter from the transmission.
2. Install a new 178-8164 Oil Seal.
3. Install a new 268-1711 Torque Converter.
4. Install the transmission and torque converter into the machine.
5. Use new 107-6826 Bolts to install the front and rear drive shafts to the transmission.
6. Install a new 1G-8878 Power Train Oil Filter.
7. Test the machine for proper operation.