PRODUCT SUPPORT PROGRAM FOR UPDATING THE SECOND REDUCTION PLANETARY OF THE FINAL DRIVES ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE SECOND REDUCTION PLANETARY OF THE FINAL DRIVES ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS

Usage:

TEBE5097-00

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14Oct2016

R120

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Before/After (Limited distribution) Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR UPDATING THE SECOND REDUCTION PLANETARY OF THE FINAL DRIVES ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS
4050 4055 7750		PS45258

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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 either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45258" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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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

31Jul2017

PROBLEM

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The existing second reduction planet gears can fail on certain 795F AC Off-Highway Trucks. If the existing planet gear fails it can cause damage to other internal components and create unplanned machine downtime.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
795F AC	ERM00168-00169, 270-276

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*****Group 2*****
795F AC	ERM00205, 264

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	2S4071	SEAL-O RING
2	7X4781	SEAL-O RING
40	9X8399	WASHER
106	1461799	WASHER-HARD
106	1470169	BOLT-HEX HEAD
2	1508791	SEAL-O-RING
6	1743045	BEARING AS. (After Failure Only)
40	1779755	BOLT-HEX HEAD
2	1804365	SEAL-O-RING
4	2920256	GEAR-PLANET (After Failure Only)
6	3088435	SHIM-PACK (After Failure Only)
4	3088436	SHIM-PACK (After Failure Only)
2	3144127	RING-TORIC
2	4287803	BEARING-BALL (After Failure Only)
8	4362596	BEARING-ROLLER (After Failure Only)
2	5160922	GEAR-SUN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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*****
2	5160922	GEAR-SUN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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****Parts Stock ****

Update (5) 326-2377 Final Drive Groups with the 516-0922 Sun Gear. Submit one claim for all (5) final drives updated.

****Affected Product****

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Refer to the Service Manual if/as necessary and see the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

(1) 516-0922 Sun Gear and 4.0 hours of labor will be allowed for each of the (5) 326-2377 Final Drive Groups that are reworked in dealer parts stock inventory.

****Affected Product****

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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*****
0-9000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
9001-15000 hrs, 13-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 78.0-hour job for Group 1 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.
Note: Submit one claim only per machine serial number (one claim per two final drives). An additional 22 hours of labor will be allowed for an after failure claim. Note: Transportation of the final drives to and from the repair facility is not being covered. Any costs associated with non-destructive testing for the inspection of gears and other components for reuse is considered to be included in the 78 hours allowed for this repair.

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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*****
0-20000 hrs, 0-60 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 0.0-hour job for Group 2
The intent of this program for Group 2 is to replace the 2nd reduction sun gears at component PCR. Since the program is to be done at PCR, no labor is allowed.

PARTS DISPOSITION

****Parts Stock****

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

****Affected Product****

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

Rework Procedure

Record in the claim the serial numbers and position (left/right) for final drives removed and installed.

Remove and rework both final drives from machine. Reference the following media form general information.

KENR8715 "Final Drive, Brake and Wheel - Remove"
KENR8715 "Final Drive, Brake and Wheel - Install"
KENR8715 "Final Drive, Brake and Wheel (Rear)- Disassemble"
KENR8715 "Final Drive, Brake and Wheel (Rear)- Assemble"

Image1.1.1

Perform the following on both final drives:
Remove the final drive cover (1), 1st reduction planetary assembly (2), ring gear (3) and second reduction planetary assembly (4).

Image1.2.1

Assemblies with over 9000 hours of operation, should have the mid-axle bearing (5) and 1st reduction planetary bearings (6) replaced.

Image1.3.1

Remove the sun gear (7) from the 2nd reduction planetary assembly.
Rotate the 2nd reduction planetary gears (8) in order to thoroughly inspect all teeth on all 4 of the gears. Any gears that do not meet reuse should be replaced with a new gear and bearings. Gears determined to be reusable can remain installed in the carrier.

Reassemble final drive

Note: In the event of a catastrophic failure or other resultant damage, additional repair may be needed before returning these assemblies to operation