| Alternator |
All Models |
All Models |
High amperage spikes resulting in regular and/or diode failures. |
Rotor slip ring machining and final inspection process improved to eliminate possibility of stray coper material being present after processing and potentially allowing short to ground conditions. Speed and feed on the lathe are controlled only by engineering or quality personnel, and they are inspected at a magnification of 200% after the operation is completed. (10/2022SRCE) |
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| Alternator |
All Models |
All Models |
Solder Issues |
Chosen a higher-grade solver solder (SAC305) with a transition period of only 8�F to avoid the environmental issues associated with traditional led solder (60/40) or a high transition period solder (97/3). (02/2021SRCE) |
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| Alternator |
Bosch 12V/135A |
125849A1R |
Brush Failure |
By removing the brush seal (not applicable on 135A alternator design), operation failures caused by seals being pulled into the rotor are eliminated. (08/2022SRCE) |
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| Alternator |
Bosch 12V/135A |
125849A1R |
High heat production and exposed circuit, Ingress of water and silicone potting, amplitude in high vibration conditions. |
Upgrade regulator/ rectifier combo by replacing the older design regulator with integrated chip-controlled regulator and Zener diode rectifiers with lower heat production and circuit protection. (04/2022SRCE) Pending: adding additional protection on regulator wire to resist water corrosion. |
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| Alternator |
Letika 12V/150A |
47389932R |
Diode Failure |
Slip ring machining operation improvements expected to reduce or resolve non-conformances. Data is being actively collected to ensure corrective action is applicable and effective with on-going in-depth diode and rectifier examination such as diode amperage limits, torque verifications (ground screws), and general heat dispersion of system. (10/2021SRCE) |
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| Alternator |
SI |
1987560C1R |
Voltage spike protections |
Regulator upgraded through the manufacture with a higher-grade Zener diode used for greater protection again voltage spikes. (10/2021SRCE) |
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| Alternator |
SI |
103804A1R |
Voltage spike protections |
Regulator upgraded through the manufacture with a higher-grade Zener diode used for greater protection again voltage spikes. (10/2021SRCE) |
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| Alternator |
SI |
ZAP804A1R |
Voltage spike protections |
Regulator upgraded through the manufacture with a higher-grade Zener diode used for greater protection again voltage spikes. (10/2021SRCE) |
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| Alternator |
SI |
103807A1R |
Voltage spike protections |
Regulator upgraded through the manufacture with a higher-grade Zener diode used for greater protection again voltage spikes. (10/2021SRCE) |
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| Alternator |
SI |
103808A1R |
Voltage spike protections |
Regulator upgraded through the manufacture with a higher-grade Zener diode used for greater protection again voltage spikes. (10/2021SRCE) |
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| Alternator |
SI |
1987560C1R |
B+ Connection failure (B+ nut loosening or relaxing) |
Initial torque specification modification and electric torque gun implementation with torque speed control allowing for controlled relaxation of joint ending at required 45in/lb clamping force. (03/2019SRCE) |
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| Alternator |
SI |
103804A1R |
B+ Connection failure (B+ nut loosening or relaxing) |
Initial torque specification modification and electric torque gun implementation with torque speed control allowing for controlled relaxation of joint ending at required 45in/lb clamping force. (03/2019SRCE) |
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| Alternator |
SI |
ZAP804A1R |
B+ Connection failure (B+ nut loosening or relaxing) |
Initial torque specification modification and electric torque gun implementation with torque speed control allowing for controlled relaxation of joint ending at required 45in/lb clamping force. (03/2019SRCE) |
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| Alternator |
SI |
103807A1R |
B+ Connection failure (B+ nut loosening or relaxing) |
Initial torque specification modification and electric torque gun implementation with torque speed control allowing for controlled relaxation of joint ending at required 45in/lb clamping force. (03/2019SRCE) |
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| Alternator |
SI |
103808A1R |
B+ Connection failure (B+ nut loosening or relaxing) |
Initial torque specification modification and electric torque gun implementation with torque speed control allowing for controlled relaxation of joint ending at required 45in/lb clamping force. (03/2019SRCE) |
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| Alternator |
SI |
1987560C1R |
High side load through bearing into bore, DE bearing bore failure |
Introductions of a new digital rotor balancer, no failures past implementation date has occurred (01/2020SRCE). |
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| Alternator |
SI |
103804A1R |
High side load through bearing into bore, DE bearing bore failure |
Introductions of a new digital rotor balancer, no failures past implementation date has occurred (01/2020SRCE). |
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| Alternator |
SI |
ZAP804A1R |
High side load through bearing into bore, DE bearing bore failure |
Introductions of a new digital rotor balancer, no failures past implementation date has occurred (01/2020SRCE). |
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| Alternator |
SI |
103807A1R |
High side load through bearing into bore, DE bearing bore failure |
Introductions of a new digital rotor balancer, no failures past implementation date has occurred (01/2020SRCE). |
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| Alternator |
SI |
103808A1R |
High side load through bearing into bore, DE bearing bore failure |
Introductions of a new digital rotor balancer, no failures past implementation date has occurred (01/2020SRCE). |
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| Alternator |
SI |
1987560C1R 21/22 |
SRE Bearing Failure due to excessive centrifugal force |
Adjusted the depth of the bushing in SRE Housing for 21SI version approx. 3.5mm deeper or flush with internal side of the frame. (03/2019) |
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| Alternator |
Prestolite |
87601413 |
Premature wear on the bearing and slip ring, misalignment on housing. |
The inner race, located on the rotor shaft, is now being replaced 100% in addition to the OEM bearing and slip ring. This improvement was made to prevent premature wear on the slip ring and bearing, improving the functioning and longevity of the alternator. Ensuring proper housing alignment prevents misalignment of the rotor shaft through the SRE bearing. Potential issues from misalightment range from grease transfer onto the slip rings (low output), accidental scoring of the slip rings by the SRE bearings (premature brush wear), or damage to the SRE bearing (premature failure). Tooling fixtures have been designed to provide the operator clear visibility ensuring that proper alignment is observed while placing the alternator halves together. (06/2020) |
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| Alternator |
Bosch |
1258491R |
Regulator clogged with field debris and overheating |
New fin design, the microcontroller-based regulator is assembled with heavy duty, premium components providing added levels of products efficiency and output. The new design prevents clogging and creates a lower temperature run rate, making the alternator less susceptible to blockage and subsequent failure due to excessive heat. These alternators also include a newly upgraded aluminum rectifier that assists in dispersing heat and preventing premature failures due to excessive heat. The rectifier upgrade consists of pressed fit, higher amperage avalanche diodes, with welded diode terminations to the lead frame for improved reliability. (08/2020) |
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| Alternator |
Bosch |
91448C2R |
Regulator clogged with field debris and overheating |
New fin design, the microcontroller-based regulator is assembled with heavy duty, premium components providing added levels of products efficiency and output. The new design prevents clogging and creates a lower temperature run rate, making the alternator less susceptible to blockage and subsequent failure due to excessive heat. These alternators also include a newly upgraded aluminum rectifier that assists in dispersing heat and preventing premature failures due to excessive heat. The rectifier upgrade consists of pressed fit, higher amperage avalanche diodes, with welded diode terminations to the lead frame for improved reliability. (08/2020) |
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| Starter |
Denso |
86982709R |
Premature failure |
This starter has been upgraded with significant changes of 100% new replacement component parts. These parts include the field case with field coil, brushes and springs, rollers and bearings, solenoid housing with coil and bracket, battery and motor contacts, solenoid plunger and contact disc/plate, plastic (S) terminal connector, and plunger return spring. (05/2020) |
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| Various Models |
Various Models |
Various PN |
Part Reclaim / Wear Properties |
Laser Clad machine implemented to salvage shafts that have experienced seal wear grooving. Material added to shaft is metallurgically bonded to increase wear resistance while not degrading base material strength. |
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| Various Models |
Various Models |
Various PN |
3D Printing of parts |
Implementation of 3D printed parts to improve the yield rate of components, and reduce cost of manufacturing. |
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| Electronics |
Elobau |
48096923R |
Internal Joystick Bracket |
Reverse engineering of bracket to machine bracket out of more robust material to eliminate failure mode of broken internal joystick components. |
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| Hydraulics |
|
Piston Pump |
Internal Wear Surface |
Resleeving of internal components to improve the wear characteristics of the components to improve the life, and increase the useful life. |
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| Driveline |
|
Draper Box Covers |
Premature Failure |
Installation of puck to improve strength and prevent premature failures of covers. Improvement of reclaim rate of existing covers to decrease manufacturing costs. |
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| Driveline |
|
Wobble Box |
Knife drive pin is falling out of the wobble box drive support housing during operation. |
Drilled and tapped the housing to secure the pin with a set screw and locktite.
* Set screw process increased the force to remove the pin from 3 Ton force to 8 Ton force eliminating the pin from backing out of the housing during sickle mover operations.
* All Reman wobble boxes with this housing and pin are updated 100% with this process. |
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| Various Models |
Various Models |
Various PN |
Part Reclaim / Wear Properties |
Laser Clad machine implemented to salvage shafts that have experienced seal wear grooving. Material added to shaft is metallurgically bonded to increase wear resistance while not degrading base material strength. |
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| Various Models |
Various Models |
Various PN |
3D Printing of parts |
Implementation of 3D printed parts to improve the yield rate of components, and reduce cost of manufacturing. |
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| Electronics |
Elobau |
48096923R |
Internal Joystick Bracket |
Reverse engineering of bracket to machine bracket out of more robust material to eliminate failure mode of broken internal joystick components. |
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| Hydraulics |
|
Piston Pump |
Internal Wear Surface |
Resleeving of internal components to improve the wear characteristics of the components to improve the life, and increase the useful life. |
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| Driveline |
|
Draper Box Covers |
Premature Failure |
Installation of puck to improve strength and prevent premature failures of covers. Improvement of reclaim rate of existing covers to decrease manufacturing costs. |
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| Hydraulics |
|
87637528R |
Creep/Nuetral Issue |
Corrective action for not setting neutral, forward, and reverse properly during assembly and final test. The work instructions have been changed to say when to set the swash plate during test and not during the assembly. Adding a fixture on test bench that properly positions the lever in F/N/R. |
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| Engines |
|
8097812R |
Leaks |
Hole in side of block is tapered. If dealer installed fitting is not properly tightened, the block will crack. Added a step open up this hole to prevent cracking of block. |
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| Hydraulics |
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5198694R |
Loud noise |
Kaizen 144 identified contamination on core parts. Audited cleaning process and inspected all warehouse stock. Recleaned all core parts. Currently in check phase. No reoccurences since audit. |
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| Driveline |
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84327512R |
|
New process to shim transmission with measuments for more actuate readings. Check phase No claims for shimming. Recent claim due to shipping damage. |
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| Engines |
|
SBA133792R |
Low oil pressure |
New oil pump is being used on this engine due to availability of previous pump. 100% inspection of cylinders with bore scope after Dyno. |
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| Engines |
|
87351542R |
Plugged galleys |
Failures due to excess silicone in the oil feed hole to the fuel injection pump. OPL created to retrain operators on the proper application of silicone. Secondary failures are head gasket leak and blowby. Starting to collect Cleco data this week to make sure all torques are complete and within spec as a precursor to the pending implemenation of Ugigami. Added a sight glass to visually check for proper flow of oil during test. |
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| Electronics |
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47372893R |
Will not stay in nuetral |
Kaizen was completed for nuetral issue. Changed adhesive used to secure potentiometer to prevent it from repositioning after installation. |
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| Hydraulics |
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84565752R |
Chatter/Noise |
Work instructions have been updated to inspect pistons for discolorization and wear. Scrap if found. Charles is monitoring all tests until Kaizen is complete. Recieved an email from warranty that we had another sprocket motor with noisy and grinding sounds. Serial number for current dealer issue 221580138. Updates on Kiazen 153, i am in the process of getting a hand held Ra tool to check the surface of the pistons to check the cylindrical surface, also I am having Owen check between new and a knowen bad piston to get a base line for the inspection process. Here is what was found thru Owen's analysis, the wear on the OD of the pistons is shown in the Cylindricity, Straightness and circularity of the report, what wear you see on the OD is reflective of the results.
My consensus is regarding why the OD wears.
Essentially, that is where the noise originates from but, it�s caused by the core bushings not having any break-in material that aligns the bushing to the cam and causes uneven distribution of force.
If we were to ever not be able to order replacement pistons, redoing the bushings in the pistons should remove the problem and the OD could be fluffed and buffed and maybe re-coated or oxidized to prevent rust in storage.
The coating on the OD of the bushings is not very thick (I don�t think it�s Teflon) but a black oxide or zinc process used. |
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| Engines |
|
84252733R |
Plugged galleys |
Failures due to excess silicone in the oil feed hole to the fuel injection pump. OPL created to retrain operators on the proper application of silicone. Secondary failures are head gasket leak and blowby. Starting to collect Cleco data this week to make sure all torques are complete and within spec as a precursor to the pending implemenation of Ugigami. Added a sight glass to visually check for proper flow of oil during test. |
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| Driveline |
|
87401155R |
Leaks |
Open Kaizen. New seal installtion cope tool made to prevent seal from rolling during installation. Double check/sign-off in place now until new tool is implemented into the process. |
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| Engines |
|
47454080R |
Coolant in oil |
2 claims 2021. Did general training on how to properly handle a liner during installation. No claims 2022 YTD |
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| Driveline |
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47933752R |
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Changed Useage to 100% new. 1 reclass claim $7278 1 rejection $4163.25. |
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| Engines |
|
87676433R |
Plugged galleys |
Failures due to excess silicone in the oil feed hole to the fuel injection pump. OPL created to retrain operators on the proper application of silicone. Secondary failures are head gasket leak and blowby. Starting to collect Cleco data this week to make sure all torques are complete and within spec as a precursor to the pending implemenation of Ugigami. Added a sight glass to visually check for proper flow of oil during test. |
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| Electronics |
|
47511724R |
Defective part |
Heat shields seperated due to the inner rivets not holding together. Engineering looking into different type of inner rivets. Received new style of inner rivets RSR3088E1 on 7/14/2022. Doing a controlled run to verify rivets are holding heat shields in place also tracking serial #'s. |
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| Driveline |
|
87546435R |
Leaks |
2 claims this year that were repairs. Spoke with Steve concerning the leak issues with both. He stated that he made sure the new operators were properly trained to the correct cleaning of the surface and installation of gaskets. |
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| Engines |
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AR174398 |
Plugged galleys |
Failures due to excess silicone in the oil feed hole to the fuel injection pump. OPL created to retrain operators on the proper application of silicone. Secondary failures are head gasket leak and blowby. Starting to collect Cleco data this week to make sure all torques are complete and within spec as a precursor to the pending implemenation of Ugigami. Added a sight glass to visually check for proper flow of oil during test. |
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| Hydraulics |
|
278188A1R |
Leaks |
Found that most of our failures are due to the inbalance of the spreader motor, running at long periods will cause shaft deflection or runout of the shaft. Checking the service manual for the installation of the motor on the spreader to see if anything is mentioned about checking the balance of the spreader wheel. I reviewed the service manual and found that the hydraulic motor does get shimmed during installation in the field or shop, This could be the cause of our failures for not shimming the spreader wheel correctly. Waiting for approval for a tag to be attached to the hydraulic motor to say STOP, read shimming instruction to prevent claim rejection. Update on the stop cation tag, Rachel is puting together a design and ordering for paint and pack. The caution tag has been approved and will start at the end of this week, 10/14/2022. |
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| Engines |
|
87422226 |
Plugged galleys |
Failures due to excess silicone in the oil feed hole to the fuel injection pump. OPL created to retrain operators on the proper application of silicone. Secondary failures are head gasket leak and blowby. Starting to collect Cleco data this week to make sure all torques are complete and within spec as a precursor to the pending implemenation of Ugigami. Added a sight glass to visually check for proper flow of oil during test. |
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| Driveline |
|
47773426R |
Leaks |
BOM was updated with updated sheild (86528254) to elimate debris getting wrapped around shield causing the gearbox to leak and housing to break. |
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| Driveline |
|
5153905R |
Inoperative |
Added correct lever height measurments, I/D check for new/core bushings anti taper paint for clutch disc clearance. |
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| Driveline |
|
47773423R |
Leaks |
BOM was updated with updated sheild (86528254) to elimate debris getting wrapped around shield cause the gearbox to leak and housing to break. |
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| Fuel |
|
84346812R |
Low pressure |
Magnet assembly (changed BOM to 80% new on 3/9/2022) |
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| Driveline |
|
86518543R |
Leaks |
Added double sign off after leak check. |
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| Engines |
|
87537667R |
Plugged galleys |
Failures due to excess silicone in the oil feed hole to the fuel injection pump. OPL created to retrain operators on the proper application of silicone. Secondary failures are head gasket leak and blowby. Starting to collect Cleco data this week to make sure all torques are complete and within spec as a precursor to the pending implemenation of Ugigami. Added a sight glass to visually check for proper flow of oil during test. |
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| Engines |
|
87603080R |
Plugged galleys |
Failures due to excess silicone in the oil feed hole to the fuel injection pump. OPL created to retrain operators on the proper application of silicone. Secondary failures are head gasket leak and blowby. Starting to collect Cleco data this week to make sure all torques are complete and within spec as a precursor to the pending implemenation of Ugigami. Added a sight glass to visually check for proper flow of oil during test. |
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| Hydraulics |
|
87648197R |
Leaks |
Issues the meter-in plug and or the steel ball and spring. Added process to check for proper seating of ball and valve. |
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| Driveline |
|
87695215R |
Inoperative |
Added enplay check on drive gear. |
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| Electronics |
|
86634125R |
Inoperative |
Added inspection of rams that are sent out to be machined. EI00005096- Requested pictures added for non-conforming excessive pitting and missing bushing. EI00005225 was opened on 6/22/2022 to update inspection criteria for the clutch gear. Tooling was added for Clutch Gear inspection and assembly process. |
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| Hydraulics |
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199142A4R |
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EI00005051 to have pictures implemented into the work instruction to prevent any build question during assembly. This also will work for the assemblers to check if the correct valve plate is getting used. Applied OPL for two different reasons, for fitting and the other was having the correct valve plate which has been corrected by an EI and OPL to show finished products for assembly. Haven't seen any issues since the OPL and EI. |
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