PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A PLATE IN THE ADAPTER GROUP ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A PLATE IN THE ADAPTER GROUP ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS

Usage:

TEBE0853-01

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21Jan2014

(Revised 08Jan2015)

U-32

A-20

D-29

O-29

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A PLATE IN THE ADAPTER GROUP ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS
3252		PI10955

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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 as soon as possible. When reporting the repair, use "PI10955" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10955" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 21Jan2014 Service Letter. Changes have been made to the SMCS codes.

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PROBLEM

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The Coupling Gp needs to be reworked on certain 795F AC Off-Highway Trucks. The existing Adapter Group can fail bearings. In the event of an Adapter group bearing failure the coupling can separate and cause damage to surrounding components. Failure of the coupling may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
795F AC	ERM00154, 163, 166, 171-173, 182, 204-205, 231-233, 235-236, 249, 256-257, 260-264, 270, 273-275

PARTS NEEDED

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Qty	Part Number	Description
8	6V3532	BOLT-HEX HEAD
8	1541580	WASHER-HARD
1	4451359	PLATE-COVER (May fabricated if not available.)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 18.0-hour job
When applicable, an additional maximum of $750.00 U.S. will be allowed for labor and materials to fabricate the plate. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the history folder for audit purposes.

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A PLATE IN THE ADAPTER GROUP ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 795F AC Off-Highway Trucks

Dear Cat Product Owner:

The Coupling Gp needs to be reworked on the product listed below. The existing Adapter Group can fail bearings. In the event of an Adapter group bearing failure the coupling can separate and cause damage to surrounding components. Failure of the coupling may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 21Jan2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 21Jan2014 Service Letter

Rework Procedure

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1. If the Plate 445-13659 is not available in the parts system it can be fabricated per Image1.1.1. Fabricate it from structural steel
(ASTM A572/A572M Grade 50
EN 10025 Grades S355: J2G3, J2G4, K2G3, and K2G4
JIS G3106 Grades SM490YA, SM490YB)

Image1.1.1

2. Remove the 338-1039 Screens from the 396-3241 Adapter Gp to access and remove the 12x M16 8T4193 Bolts and 3E-4356 Washers that fasten the 395-4220 Coupling Gp-Flexible to the engine flywheel.
3. Support the adapter gp.
4. Remove the 16x M12 8T-4194 Bolts and 039-8557 Washers that fasten the adapter gp to the flywheel housing.

Image1.2.1

5. Remove the adapter gp and coupling as. together and support the adapter gp with the coupling as. facing up.
CAUTION: the Coupling As. is not restrained on the adapter gp star-hub and can slip off during removal of the adapter gp. If preferred, the adapter gp and coupling as. can be removed individually, then the coupling as. re-installed on the star-hub before proceeding with the next step. Lubricate the blades of the star-hub with 5N-5561 before re-installing the coupling as.
6. Remove the 16x M22 219-4481 Bolts and 5P-8249 Washers that fasten the star-hub to the drive-hub.

Image1.3.1

7. Install two M10 lifting-eyes or lifting-links into the star-hub.
8. Lift the star-hub & coupling as. together off the drive-hub of the adapter gp.

Image1.4.1

9. Check that the shaft in the adapter gp turns freely, and there is not excessive radial or axial play in the shaft, or noise emitting from the bearings. If necessary, replace the bearings in the adapter gp.
10. Turn the coupling as. over with the star-hub inside.
11. Remove the eight M20 bolts that fasten the cover on the coupling as. The bolts will not be reused.

Image1.5.1

12. Remove the slotted cover from the coupling as.

Image1.6.1

13. Install the new cover-plate without slots fabricated per Image1.1.1. The face with the radius on the ID and chamfer on the OD goes against the blue silicone elements.
14. Install new eight M20 6V-3532 Bolts and 154-1580 Washers that fasten the cover-plate to the coupling as. and tighten to 460 +/- 60 Nm (340 +/- 44 lb ft) in a star pattern. Repeat until no further bolt movement.

Image1.7.1

15. Turn the coupling as. back over with the star-hub now captured inside.
16. Lift the star-hub & coupling as. and install onto the drive-hub of the adapter gp. Insure the star-hub is fully seated onto the drive-hub.

Image1.8.1

17. Install the 16x M22 219-4481 Bolts and 5P-8249 Washers that fasten the star-hub to the drive-hub. Tighten the bolts to 620 +/- 80 Nm (457 +/- 59 lb ft) in a star pattern.

Image1.9.1

18. Install two M16 lifting-eyes or lifting-links into the adapter gp housing.
19. Support the adapter gp (with coupling as. installed) and align it with the flywheel housing. Guide-Rods can be used to help with the alignment.
20. Start the 16x M12 8T-4194 Bolts and 039-8557 Washers that fasten the adapter gp to the flywheel housing ? do not tighten the bolts at this time. Maintain support of the adapter gp.

Image1.10.1

21. Turn the yoke as required to align the holes in the flange of the Coupling As. with the threaded holes in the flywheel.
22. Start the 12x M16 8T4193 Bolts and 3E-4356 Washers that fasten the coupling as. to the engine flywheel ? do not tighten the bolts at this time.

Image1.11.1

23. Tighten the 16x M12 bolts that fasten the adapter gp to the flywheel housing to 100 +/- 20 Nm (74 +/- 15 lb ft) in a star pattern.

Image1.12.1

24. Tighten the 12x M16 bolts that fasten the coupling as. to the engine flywheel to 240 +/- 40 Nm (177 +/- 30 lb ft) in a star pattern.
25. Remove the support from the adapter gp.
26. Install the screens using six M6 8C-3210 Bolts. Tighten the Bolts to 12 +/- 3 Nm (9 +/- 2 lb ft).