MINING &

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24H Motor Grader

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24H Motor Grader

Blade Beams

Problem
138-7428 circle fails through the blade beams. Cracks have
originated at the tail of gusset, through gusset, end of diaper plate and
near lower pin bosses
Blade beams go from small fatigue crack to brittle fracture
immediately.
Inadequate structure for given application.

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24H Motor Grader

Blade Beams
Current Status/Action
Redesigned blade beams to increase
strength.
Validated through FEA and stress test.

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24H Motor Grader

Blade Beams
Beam design
Box section
C Channel casting
Integrated gusset

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24H Motor Grader

Blade Beams
160mm
60mm

30mm
30m
m

30mm

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24H Motor Grader

Blade Beams

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24H Motor Grader

Blade Beams

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24H Motor Grader

Blade Beams

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24H Motor Grader

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24H Motor Grader

Blade Beams

Factory implementation on 7kk93

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24H Motor Grader

Blade Beam Failures

Gusset

Diaper Plate

Failure thru gusset.

Failure @ tail of gusset.

Blade Beam

Failure @ intersection of diaper plate & Blade

Beam

Failure @ boss & Blade beam -- Outboard face.

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24H Motor Grader

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24H Motor Grader

30mm Plates with five 4 X 1 5/8

oval (egg shaped) holes
Nice welds!!

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24H Motor Grader

This is the 40mm gusset plate

note: one pass on top side to
reduce stress risers from
blow through

This portion of the circle needs

a 40mm chamfer to allow for
thicker plate

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Placement of the
gussets
We did not remove the
pins or rebore

24H Motor Grader

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CONSTRUCTION
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Note the smoothing of

the transition
on the diaper plate

24H Motor Grader

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24H Motor Grader

We removed the coil and valve

cartridge and installed a plug
this insures that the Blade
Cushion accumulator
will remain active

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24H Motor Grader

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24H Motor Grader

Engine Enclosure

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24H Motor Grader

Engine Enclosure

Cracking
occurs at low
hours

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24H Motor Grader

Engine Enclosure
Several design changes have been tested
Gussets at the bottom of tube structure
Rubber mounted enclosure
Isolate enclosure from radiator structure
Attach enclosure to fuel tank
Test results and analysis indicate that this is a dynamic problem
Modal frequency analysis of the machine has been completed
Engineering will work this problem concurrently with Tier III Emissions
Update

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24H Motor Grader

Engine Harness

Problem
Wiring harness 155-3625 becomes brittle in area routed near
muffler/turbo. Harness braiding and wire insulation sloughs leading
to electrical system malfunction and/or open and shorted electrical
circuits.
Current Status/Action
Harness assembly treated in critical area with heat resistant material.
Clip added to further control routing near the muffler.

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24H Motor Grader

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24H Motor Grader

460mm (18in) Heat Sleeve

Clip to Valve Cover Bolt

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24H Motor Grader

Engine Harness

Factory Implementation
Harness and wiring group changes in production 7kk100.

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24H Motor Grader

Misc Product Updates

Rear Defrost Fan (7kk200)
Adds second defrost fan and fan
control
Autolube (7kk201)
New reservoir and pump
Injector cap retainer
Adds injector labels

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24H Motor Grader

Misc Product Updates

Blade Cushion (7kk95)
Accumulators always active
Implemented in two phases

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24H Motor Grader

24H DIFFERENTIAL

B4 Bearing

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24H Motor Grader

ROOT CAUSE
Three failed bearings were sent back to the supplier for analysis
The suppliers report stated all three bearings experienced surface origin
flaking that is likely a result of poor or insufficient oil film thickness.
The report also stated excessive loading did not contribute to the failure
as the relatively shallow nature of the flaking is not consistent with that
caused by excessive loading.

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24H Motor Grader

B4 bearing Lubrication
Bath Lube
SAE 30W oil
Not filtered

Rotating seals for differential

lock inhibit oil flow.
Lack of oil flow
Reduces oil film thickness
Causes localized heat generation
Higher temps reduce oil viscosity
Reduces oil film thickness even further

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24H Motor Grader

SOLUTION
Add forced lubrication to
backside of bearing
Filter 100% of oil
through pump
Maintain 4F2041 race
Replace 2D9547 with 1784642
bearing
Designed for applications
with poor lubrication

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24H Motor Grader

Re-route lube for reverse side of

bevel - pinion gear mesh

Crimp end of tube to the

forward side of gear mesh
Creates back
pressure for better oil
flow to B4
Creates spray pattern
to cover more of tooth
profile

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24H Motor Grader

Tube routed to maximize
clearance with rear axle
housing during assembly

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24H Motor Grader

FILTRATION OF DIFFERENTIAL OIL

Moved relief valve from

pump to after filter

All oil must flow

through filter
Rear Axle

Current

Rear Axle

Update

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24H Motor Grader

Moved transmission filter 316 mm for

easier filter service
Request from Shop & Customer
Change to shield for valve
mounting

New Relief Valve - 207-8214

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24H Motor Grader

Thrust Washer Bolted Joint Failure

Increase quantity of screws from

two to four
Increase counter bore in
housing to 5.5 mm - greater
stretch length
Add Loc-Tite to thrust washer
Resolves joint loosening
problems
Four screw pattern retrofits to
two screw pattern - no new P/N

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24H Motor Grader

8X8995 Lines Group - Fuel

o

Added 45 elbow for clearance with

turbocharger
Reduces thermal hardening
and cracking
Re-routed lines for better
access to filter

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Pin retention

24H Motor Grader

Structures

Lean pin
retention

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24H Motor Grader

Structures
Old design
Retained with bolt

Current design

Rear View of Axle End

Pin As. With cap & 2

bolt plate
Pin allowed to rotate

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24H Motor Grader

Structures

Bolts loosening due to

plate bending

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24H Motor Grader

Structures

New design:
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Allows pin and cover to

move together
No relative movement
between bolts/spacer

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24H Motor Grader

Structures

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24H Motor Grader

Structures

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24H Motor Grader

Structures

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24H Motor Grader

Structures

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24H Motor Grader

Agenda
Transmission/Torque Converter
Dave Spurlock
Yokes
Bearings/Clutch Failures
Clutch Adjustment
Questions and Discussions

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There have been reports of spline wear in the input yoke, and also case
breakage around the lower gear bearing cage.

Current Status/Action

Transmission Input Transfer Gearbox

Problem

24H Motor Grader

The 121-3173 Yoke As was changed to have improved hardness to resist wear.
The change went into effect OCT 1999. There was no part number change.
Early reports of input case breakage were found to be a result of harsh lockup
clutch engagement, which was addressed with software changes plus the
addition of a lockup clutch pressure sensor. This allows high torque spikes
caused by hitting solid objects with the blade to cause the lockup clutch to slip,
thereby acting as a fuse to protect the drivetrain.
More recent failures on machines with the above changes may be due to loose
bearing cage bolts.

Targeted Resolution Date:

N/A

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24H Motor Grader

Input Transfer Gearbox Breakage

Housing failures related to the lockup clutch should have been resolved
with addition of lockup clutch pressure sensor and 149-5164 (or higher)
software (149-5163 or higher ECM)

Loose bolt theory based on a dealer failure report

Bolted joint analysis does not show problems

Gearbox very similar to 988/834/836 (all use 8E-5872 Case As)

Only two reports against 988FII (none against 834 or 836)

One claims misalignment of housing bores

One claims cracked housing, but no details available (no claim filed)

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Clutch material wears and/or burns in clutch #5 in the 24H transmission. The most
significant issue is repeat failures at low hours on several machines.

Current Status/Action

Clutch 5 Failures

Problem

24H Motor Grader

The root cause is suspected to be incorrect assembly of the 136-1020 bearing in

the forward planet carrier. This is a thrust ball bearing that must be installed in a
specific orientation. If installed backwards, the bearing allows the carrier and other
parts (including the #5 clutch hub) to move axially. This results in contact between
the clutch #5 hub and piston, preventing the piston from applying full clamping
pressure to the clutch pack.
Feedback from machines with repeat failures has been requested. It is desired to
know the orientation of the 136-1020 bearing. A bearing that was installed
backwards will show a wear or spalling pattern outside of the ball groove on the
outer race.
Original Service Manual did not specify bearing orientation. Service
Magazine article explaining correct orientation of bearing was published
18 Dec 2000.

Targeted Resolution Date:

Unknown at this time.

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136-1020 Bearing

Carrier can move

towards output end
of planetary, forcing
clutch hub to contact
piston before clutch
pack is fully compressed

24H Motor Grader

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24H Motor Grader

136-1020 Bearing
Side with thick outer race that has
part number and thrust markings must
face down at assembly so that it faces
towards the Reverse planetary.

Side with thin outer race that has

no markings faces up and has the
retaining ring assembled against it.

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The 24H transmission requires an adjustment to clutch #2 and #5 when the

clutches are rebuilt. This is unique to the 24H transmission.

Current Status/Action

Clutch Adjustment

Problem

24H Motor Grader

The 24H transmission is a derivative of the 988 transmission. To get six

forward speeds it uses three speed ranges with a forward low and forward high
clutch. Shifts from 2F to 3F require two clutches (#2 and #5) to be filled, which
can result in a shift hesitation and/or harshness.
These two clutches have setscrews that limit how far the clutch piston can
retract. By controlling this distance, the amount of oil required to fill the clutch
is controlled, minimizing clutch fill time and minimizing shift
harshness/hesitation problems.
Failure to adjust these screws at rebuild may result in harsh shifts or premature
clutch wear.

Targeted Resolution Date:

N/A

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24H Motor Grader

Ground Engaging Tools

Implement
Operator
Technique
2000 Edition

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24H Motor Grader

MG Operator Technique

Operator Technique
Do not
not use
excessive speed
Do not
not use
excessive downward
pressure
Use accumulator to
absorb shocks

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24H Motor Grader

Speed
+
Downward Pressure
=
Wear

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24H Motor Grader

MG Operator Technique

Operating Speeds
Typical applications are
performed under 6 MPH
The 16H has four forward
speeds under 6 mph, the
24H has three forward
speeds under 6 mph
In many situations the 24H
will be operated at one gear
lower than 16H because of
differences in the gear
ratios

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MG Operator Technique
24H Motor Grader

Heat affected. Probably

due to excessive speed

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24H Motor Grader

MG Operator Technique
Heat affected. Probably
due to excessive speed

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24H Motor Grader

MG Operator Technique

Cast angle affects

productivity
Critical for proper use
of GraderBit system

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24H Motor Grader

MG Operator Technique

Blade angle affects

wear pattern and rate
of wear

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24H Motor Grader

MG Operator Technique

Best angle for penetration

and edge wear
For productivity start with
top of blade 2 inches (4
inches for the 24H) in
front of the toe

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24H Motor Grader

MG Operator Technique

Tip angle
Moldboard tipped forward
for initial penetration

Cutting Position: top of

moldboard slightly ahead of
cutting edge

Moldboard racked all

the way back to spread,
carry or comb

On a 24H the difference in cutting edge depth in rolling

MB back and tipping forward is 280 mm, (11 inches).

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24H Motor Grader

MG Operator Technique

Use an aggressive forward tip for initial penetration of hard packed material. Fig. 1
Once penetration is made, tip the moldboard back for optimum cutting position.
Most standard road cutting applications use the top of the moldboard slightly ahead of

the cutting edge. Fig. 2 A = 2 inches except the 24H = 4 inches

Roll the moldboard back to carry, spread or comb out oversized rocks, Fig. 3.

Wear
Rate

Figure 1

Figure 2

Figure 3

A
High

Moderate
to High

Low

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24H Motor Grader

MG Operator Technique

Moldboard Positioning

Tip the moldboard forward to cut hard packed material and tip it
back for processing, carrying, and combing out oversized rock.

Turn on blade cushion system when cutting.

Use the thinnest cutting edge that material and conditions will allow
to:

Improve material rolling action

Increase moldboard penetration downforces
Reduce required horsepower to power the grader through the cut,
improving both fuel consumption and tire wear
Reduce
GET costs
Using theblade
angle
properly will reduce rimpull, fuel
consumption and extend cutting edge life
It is an operator requirement to maintain a proper cutting edge to
reduce operating costs

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24H Motor Grader

MG Operator Technique
Operator believed there was a
problem with the edge

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24H Motor Grader

MG Operator Technique

Incorrect
Blade laid back too far

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24H Motor Grader

MG Operator Technique

Angle of wear denotes the angle of operation

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24H Motor Grader

MG Operator Technique

Blade angle affects wear pattern,

rate of wear and penetration
Start with moldboard 2(24H =
4) ahead of the toe adjust to
material conditions

Incorrect
Incorrect

Large
Large
footprint
footprint
Best position for cutting edge is
Excessive
Excessive
90 degrees to the road
wear
wear
Laid back reduces penetration
Reduced
Reduced
and can wear moldboard
penetration
Fixed angle maintains constant penetration
edge thickness for longer life
Changing angle often wears the
sharpened edge quickly,
shortening life but can be
used to sharpen cutting edge

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24H Motor Grader

MG Operator Technique

Haul Road Maintenance

It is important to pull enough material from the berms to build up the road
surface and fill in low areas.

Leave rocks smaller than 2 in diameter on the road surface to provide

additional traction to trucks when the road surface is wet.

Comb the larger rocks off the road surface.

These can slow the flow of

water in the ditches and retard erosion.

Always begin road maintenance at one end of the working section.

When possible, make the initial pass in the same direction as truck traffic.

The windrow serves as an indicator to approaching trucks a grader is ahead

Technique prevents leaving bends in the windrow, maneuvering around
oncoming traffic (which could cause safety hazards) and production
inefficiencies.

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24H Motor Grader

MG Operator Technique

A
A good
good understanding
understanding of
of ripper
ripper usage
usage will
will reduce
reduce costs
costs
Ripping
Ripping prior
prior to
to cutting
cutting hard
hard packed
packed material
material will
will greatly
greatly reduce
reduce
cutting
cutting edge
edge wear
wear

The figure below shows a typical sections that should be ripped

The road way cross slope should be maintained at a 2% to 4% angle.
It is very typical to find what is called quarter crowns.
The bottom solid line shows a proper cross-slope.
The top dashed line shows the quarter crown which should be ripped prior
to removal

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24H Motor Grader

MG Operator Technique

Another
Another area
area that
that needs
needs to
to be
be ripped
ripped prior
prior to
to blading
blading is
is where
where
there
there are
are potholes
potholes

There are two ways to fix a road with potholes

1. Make a cut that is as deep as the deepest hole
2 .Use the ripper

Then blade material back across the area to maintain the proper roadway
template

Ripping or cutting to the bottom of the holes is to reestablish uniform density

If the area is not ripped or cut the material placed in the holes will not stay
It will not bond to the hard undisturbed material on the bottom

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24H Motor Grader

MG Operator Technique

The
The figure
figure below
below shows
shows aa typical
typical section
section where
where material
material gets
gets
pushed
pushed out
out of
of aa hole
hole and
and mounds
mounds around
around the
the area
area making
making
conditions
conditions even
even worse
worse

If the bottom of the hole is not loosened prior to filling, the material will return
to this position shortly after the trucks start running over it

If it is ripped, watered, bladed and compacted properly, maintenance will be

greatly reduced

In this situation it is recommended ripping be used over excessive cutting. It

requires less material movement and greatly extends cutting edge life
Direction of Travel

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24H Motor Grader

I L L A R

G R O U N D

E N G A G I N G

T O O L S