PRODUCT IMPROVEMENT PROGRAM FOR MEASURING AND ADJUSTING THE PUMP DRIVE BEARING PRELOAD ON CERTAIN 794 AC, 795F AC, 796 AC, 797F AND 798 AC OFF-HIGHWAY TRUCKS
Usage:
TEBE8746-02
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| 11Feb2019 |
| (Revised 03Apr2019) |
U-52
A-42
D-45
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| Priority Parts stock action needed | PRODUCT IMPROVEMENT PROGRAM FOR MEASURING AND ADJUSTING THE PUMP DRIVE BEARING PRELOAD ON CERTAIN 794 AC, 795F AC, 796 AC, 797F AND 798 AC OFF-HIGHWAY TRUCKS |
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| 3108 | PI32985 |
|
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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 "PI32985" 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 "PI32985" 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: | 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, "7751" as the Group Number, "56" as the 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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| NOTE: | This Revised Service Letter replaces the 11Feb2019 (Revised 25Mar2019) Service Letter. Changes have been made to the Affected Product. |
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COMPLETION DATE |
TERMINATION DATE |
| 31Aug2019 | 29Feb2020 |
PROBLEM
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| The bearing adjustment on the 148-7397 and 148-7399 Gears needs to be measured and adjusted on certain 794 AC, 795F AC, 796 AC, 797F and 798 AC Off-Highway Trucks. The existing bearings may have an incorrect end play adjustment. In addition, the 148-7398 Idler Gear may be positioned incorrectly. An incorrect end play adjustment and gear position can result in a low hour pump drive failure. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| 794 AC | HRT00101 MT500102-00107, 119-141 |
| 796 AC | HRZ00500 |
| 798 AC | ST700400 |
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| *******Group 2******* | |
| 795F AC | ERM00299-00300 |
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| *******Group 3******* | |
| 797F | LAJ00651-00653, 657-658 LTZ00142-00146 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 2H6338 | SEAL-O-RING |
| 1 | 5P5846 | SEAL-O-RING |
| 2 | 6V3349 | SEAL-O-RING |
| 2 | 6V5101 | SEAL-O-RING |
| 2 | 6V5553 | SEAL-O-RING |
| 2 | 1523853 | SHIM-PACK |
| 1 | 1612352 | SHIM-PACK |
| 7 | 2287089 | SEAL-O-RING-ORFS |
| 3 | 2287090 | SEAL-O-RING-ORFS |
| 2 | 2287092 | SEAL-O-RING-ORFS |
| 1 | 2287093 | SEAL-O-RING-ORFS |
| 1 | 2287095 | SEAL-O-RING-ORFS |
| 2 | 2352475 | SEAL-RECTANGULAR |
| 4 | 2352476 | SEAL-RECTANGULAR |
| 1 | 2697885 | SEAL-O-RING |
| 1 | 2986387 | SEAL-O-RING |
| 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. |
||
| *******Group 2******* | ||
| 1 | 2H6338 | SEAL-O-RING |
| 1 | 5P5846 | SEAL-O-RING |
| 2 | 6V3349 | SEAL-O-RING |
| 3 | 6V4590 | SEAL-O RING |
| 2 | 6V5101 | SEAL-O-RING |
| 2 | 6V5553 | SEAL-O-RING |
| 3 | 1241859 | SEAL-O-RING |
| 2 | 1523853 | SHIM-PACK |
| 1 | 1612352 | SHIM-PACK |
| 1 | 1705715 | SEAL-O-RING |
| 21 | 2287089 | SEAL-O-RING-ORFS |
| 1 | 2287090 | SEAL-O-RING-ORFS |
| 5 | 2287093 | SEAL-O-RING-ORFS |
| 1 | 2287095 | SEAL-O-RING-ORFS |
| 1 | 2343544 | SEAL-O-RING |
| 1 | 2352475 | SEAL-RECTANGULAR |
| 3 | 2352476 | SEAL-RECTANGULAR |
| 1 | 2697885 | SEAL-O-RING |
| 1 | 2986387 | SEAL-O-RING |
| 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. |
||
| *******Group 3******* | ||
| 1 | 5P5846 | SEAL-O-RING |
| 1 | 6V1195 | SEAL-O-RING |
| 2 | 6V3349 | SEAL-O-RING |
| 1 | 6V4590 | SEAL-O RING |
| 1 | 6V5553 | SEAL-O-RING |
| 4 | 8T0568 | SEAL-O-RING |
| 2 | 1523853 | SHIM-PACK |
| 1 | 1612352 | SHIM-PACK |
| 1 | 1705715 | SEAL-O-RING |
| 16 | 2147568 | SEAL-O-RING-STOR |
| 9 | 2287090 | SEAL-O-RING-ORFS |
| 1 | 2352475 | SEAL-RECTANGULAR |
| 6 | 2352476 | SEAL-RECTANGULAR |
| 1 | 2352482 | SEAL-RECTANGULAR |
| 1 | 2385082 | SEAL-O-RING-STOR |
| 3 | 2385084 | SEAL-O-RING-STOR |
| 1 | 2385086 | SEAL-O-RING-STOR |
| 1 | 2697885 | SEAL-O-RING |
| 1 | 2986387 | SEAL-O-RING |
| 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 |
SERVICE CLAIM ALLOWANCES
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|
Claim 16 hours labor for pump drive D&A for each pump drive that is in stock |
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| *******Group 1******* | |||||
| NOTE: This is a 36.0-hour job for Group 1 | |||||
| This is a 36 hour job. This includes 24 hours to remove and install components and 12 hours to disassemble and assemble pump drive. |
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| *******Group 2******* | |||||
| NOTE: This is a 36.0-hour job for Group 2 | |||||
| This is a 36 hour job. This includes 24 hours to remove and install components and 12 hours to disassemble and assemble pump drive. |
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| *******Group 3******* | |||||
| NOTE: This is a 36.0-hour job for Group 3 | |||||
PARTS DISPOSITION
| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| EXAMPLE COPY OF OWNER NOTIFICATION XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR MEASURING AND ADJUSTING THE PUMP DRIVE BEARING PRELOAD ON CERTAIN 794 AC, 795 AC, 796 AC AND 798 AC OFF-HIGHWAY TRUCKS MODELS INVOLVED - 794 AC, 795 AC, 796 AC, 798 AC Off-Highway Trucks Dear Cat Product Owner: The pump drive needs to be inspected on the products listed below. The existing pump drive can fail due to incorrect bearing end play adjustment. 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. Please refer the dealer to their Service Letter dated 11Feb2019 when scheduling this service. We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime. Caterpillar Inc. Identification #(s) Attached to 11Feb2019 Service Letter |
| 794 AC 396-9741 DRIVE PUMP REWORK 1. Remove drive shaft. Reference Media Number UENR2270, "Disassembly and Assembly, 794 AC Off-Highway Truck Machine Systems", "Drive Shaft (Main) - Remove and Install". 2. Remove hoist pump. Reference Media Number UENR2271, "Disassembly and Assembly, 794 AC Off-Highway Truck Machine Systems", "Gear Pump (Hoist) - Remove and Install". 3. Remove fan pump. Reference Media Number UENR2271, "Disassembly and Assembly, 794 AC Off-Highway Truck Machine Systems", "Piston Pump (Hydraulic Fan) - Remove and Install". 4. Remove steering pump. Reference Media Number UENR2271, "Disassembly and Assembly, 794 AC Off-Highway Truck Machine Systems", "Piston Pump (Steering) - Remove and Install". 5. Remove pump drive from truck. Reference Media Number UENR2271, "Disassembly and Assembly, 794 AC Off-Highway Trucks Machine Systems", "Pump Drive -Remove and Install". 6. Disassemble pump drive to take bearing shim pack measurements. Reference Media Number UENR2271, "Disassembly and Assembly, 794 AC Off-Highway Truck Machine Systems", "Pump Drive - Disassemble". 7. Measure for correct shim pack thickness. Adjust the shim pack as needed. Inspect idler gear for correct position. Part number on gear should be installed face up. Reference Media Number UENR2271, "Disassembly and Assembly, 794 AC Off-Highway Truck Machine Systems", "Pump Drive - Assemble". See Image 1.1.1 for pump drive replacement part locations. (1) 152-3853 SHIM PACK (2) 161-2352 SHIM PACK (3) 269-7885 SEAL O-RING (4) 5P-5846 SEAL O-RING (5) 6V-3349 SEAL O-RING (6) 298-6387 SEAL O-RING (7) 6V-5553 SEAL O-RING 8. Assemble pump drive to truck. 9. Reference media numbers in Steps 1 through 4 to install drive shaft, hoist, fan and steering pumps to pump drive. See Image 1.1.2, Image 1.1.3 and Image 1.1.4 and the following parts list for seal replacement locations. (8) 235-2476 SEAL-RECTANGULAR (9) 6V-5101 SEAL O-RING (10) 235-2475 SEAL-RECTANGULAR (11) 228-7092 SEAL O-RING (12) 228-7093 SEAL O-RING (13) 2H-6338 SEAL O-RING (14) 228-7089 SEAL O-RING (15) 228-7090 SEAL O-RING (16) 228-7095 SEAL O-RING |
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| Image1.1.1 |
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| Image1.1.2 |
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| Image1.1.3 |
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| Image1.1.4 |
| 795 AC 397-9455 DRIVE PUMP REWORK 1. Remove drive shaft. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Pump Drive Shaft - Remove and Install". 2. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Gear Pump (Brake Actuation) - Remove". 3. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", Gear Pump (Brake Cooling) - Remove". 4. Remove hoist pump. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Gear Pump (Hoist) - Remove". 5. Remove fan pump. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Piston Pump (Fan Drive) - Remove". 6. Remove steering pump. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Piston Pump (Steering) - Remove". 7. Remove pump drive from truck. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Pump Drive - Remove". 8. Disassemble pump drive to take bearing shim pack measurements. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Pump Drive - Disassemble". 9. Measure for correct shim pack thickness. Adjust the shim pack as needed. Inspect idler gear for correct position. Part number on gear should be installed face up. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Pump Drive - Assemble". See Image 1.2.1 for pump drive replacement part locations. (1) 152-3853 SHIM PACK (2) 161-2352 SHIM PACK (3) 269-7885 SEAL O-RING (4) 5P-5846 SEAL O-RING (5) 6V-3349 SEAL O-RING (6) 298-6387 SEAL O-RING (7) 6V-5553 SEAL O-RING 10. Assemble pump drive from truck. Reference Media Number KENR8727, "Disassembly and Assembly, 795F and 795F AC XQ Off-Highway Truck Machine Systems", "Pump Drive - Install". 9. Reference to media numbers in Steps 1 through 6 to "Install" pump drive shaft, brake actuation, brake cooling, hoist, fan drive and steering pumps to pump drive. See Image 1.2.2, Image 1.2.3 and Image 1.2.4 and the following parts list for seal replacement locations. (16) 6V-4590 SEAL O-RING (17) 124-1859 SEAL O-RING (18) 2H-6338 SEAL O-RING (19) 235-2475 SEAL-RECTANGULAR (20) 170-5715 SEAL O-RING (21) 234-3544 SEAL O-RING (22) 6V-5101 SEAL O-RING (23) 235-2476 SEAL-RECTANGULAR (24) 228-7089 SEAL O-RING (25) 228-7090 SEAL O-RING (26) 228-7093 SEAL O-RING (27) 228-7095 SEAL O-RING |
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| Image1.2.1 |
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| Image1.2.3 |
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| Image1.2.4 |
| 797F and 797F XQ 386-4902 DRIVE PUMP REWORK 1. Remove drive shaft. Reference Media Number KENR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Drive Shaft (Hydraulic) - Remove and Install". 2. Remove hoist pump. Reference Media Number KENR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Gear Pump (Brake, Hoist) - Remove and Install". 3. Remove brake and rear axle lubrication pump. Reference Media Number KENR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Gear Pump(Brake, Rear Axle Lubrication) - Remove and Install". 4. Remove brake cooling piston pump. Reference Media Number KENR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Piston Pump (Brake Cooling) - Remove and Install". 5. Remove hydraulic fan and steering pump. Reference Media Number KENNR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Piston Pump (Hydraulic Fan, Steering) - Remove and Install". 6. Remove pump drive from truck. Reference Media Number KENR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Pump Drive - Remove and Install". 7. Disassemble pump drive to take bearing shim pack measurements. Reference Media Number UENR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Pump Drive - Disassemble". 8. Measure for correct shim pack thickness. Adjust the shim pack as needed. Inspect idler gear for correct position. Part number on gear should be installed face up. Reference Media Number KENR8382, "Disassembly and Assembly, 797F and 797F XQ Off-Highway Truck Machine Systems", "Pump Drive - Assemble". See Image 1.3.1 for pump drive replacement part locations. (1) 152-3853 SHIM PACK (2) 161-2352 SHIM PACK (3) 269-7885 SEAL O-RING (4) 5P-5846 SEAL O-RING (5) 6V-3349 SEAL O-RING (6) 298-6387 SEAL O-RING (7) 6V-5553 SEAL O-RING 9. Assemble pump drive to truck. Reference media number KENR8382. "Disassembly and Assembly 797F and 797F XQ Off-Highway Truck Machine Systems", "Pump Drive - Remove and Install". 10. Reference media numbers in Steps 1 through 5 to install drive shaft, hoist, rear axle lubricating ,brake cooling and steering pumps to pump drive. See Image 1.3.2, Image 1.3.3, Image 1.3.4, image 1.3.4, image 1.3.5, image 1.3.6 and image 1.3.7 for the following parts list for seal replacement locations. (8) 235-2476 SEAL-RECTANGULAR (10) 235-2475 SEAL-RECTANGULAR (15) 228-7090 SEAL O-RING (16) 8T-0568 Seal O-Ring (18) 238-5084 Seal O-Ring (19) 238-5082 Seal O-Ring (20) 170-5715 Seal O-Ring (21) 6V-4590 Seal O-Ring (22) 214-7568 Seal O-Ring (23) 6V-1195 Seal O-Ring (24) 238-5086 Seal O-Ring |
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| Image1.3.1 |
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| Image1.3.7 |
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