PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CLUSTER GEAR STUB SHAFT FLANGE BOLTS AND CLUSTER GEAR RETAINING PLATE BOLTS ON CERTAIN C175 GENERATOR SETS AND 793F , 793F XQ, 795F AC, 797F, 797F XQ OFF-HIGHWAY TRUCKS Caterpillar


PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CLUSTER GEAR STUB SHAFT FLANGE BOLTS AND CLUSTER GEAR RETAINING PLATE BOLTS ON CERTAIN C175 GENERATOR SETS AND 793F , 793F XQ, 795F AC, 797F, 797F XQ OFF-HIGHWAY TRUCKS

Usage:

REBE7579-01

04Oct2011
(Revised 10Jan2012)


U-419
A-350
D-374
O-370

 

Before/After

  
 Parts stock action needed 

PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CLUSTER GEAR STUB SHAFT FLANGE BOLTS AND CLUSTER GEAR RETAINING PLATE BOLTS ON CERTAIN C175 GENERATOR SETS AND 793F , 793F XQ, 795F AC, 797F, 797F XQ OFF-HIGHWAY TRUCKS

1204 1206 7553
PS43399
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 "PS43399" 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.

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.

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.

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.

 
NOTE:

This Revised Service Letter replaces the 04Oct2011 Service Letter. Changes have been made to the Affected Product and Service Claims Allowances.


TERMINATION DATE

31Oct2013

PROBLEM

The existing stub shaft plate bolts and cluster gear retainer plate bolts may have not been tightened properly and can fall out on certain C175 Generator Sets, 793F , 793F XQ, 795F AC, 797F, 797F XQ Off-Highway Trucks. If the existing plate bolts fall out it can cause excessive oil to come out of the breathers and oil pressure loss.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
793F  SSP00112-00483
793F XQ  SND00100-00114
795F AC  ERM00161-00196
797F  LAJ00141-00310
797F XQ  WSP00100-00107
*******Group  2*******
C175-16  WYB00100-00112, 114-118, 124-129, 131, 135-136, 138-454, 456-528

PARTS NEEDED

No parts needed for this program

ACTION REQUIRED

****Parts Stock ****

Rework the following engines in dealer parts stock and/or dealer exchange inventory:

250-7100, 281-6501, 314-2485, 360-1646, 365-9318, 365-9319, 365-9320, and 365-9321 Service Replacement C175-16 Engines with a B7B prefix
Rework all engines built prior to B7B00537.

288-8962, 300-8722, 314-2486, 328-1440, 328-1440, 365-9324, 365-4345, 365-9325, 365-4345 Service Replacement C175-16 Engines with a JTL prefix
Rework all engines built prior to JTL00256.


239-2330, 306-7651, 307-9788, 339-0333 Service Replacement C175-16 Engines with a WYB prefix
Rework all engines built prior to WYB00529.

262-1300, 282-2060, 360-1647, 365-9326, 365-9327, 365-9328, and 365-9329 Service Replacement C175-20 Engines with a LLM prefix
Rework all engines built prior to LLM00349.

Refer to the Action Required for the Affected Product for the rework procedure.

 
 
****Affected Product****
Refer to the attached Rework Procedure.

Note: Engines with more than 2000 hours of operation do not need to perform this service letter.

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for all parts inspected in dealer parts stock.

 
 
****Affected Product****
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-2000 hrs,
0-12 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 4.0-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.


Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-2000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 4.0-hour job for Group 2

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.




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


 
1. Remove the Cam Timing Sensor Cover (A) and the Crank Sensor Cover (B) from the rear housing.

2. Using a borescope with a 90 degree mirror, inspect the Cam Thrust Plate for loose bolts by routing the borescope through the Cam Timing Sensor Cover (A) and the Crank Sensor Cover (B).

Note: In order to view the bolts on the bottom of the plate you must route the borescope through the crank sensor cover (B). A flexable but rigid tube similar to copper may be used to guide the scope into position.
Image1.1.1
 
Identifying a loose bolt on the stub shaft plate

Factory Process:

1. The bolts are installed with an initial torque of 30 N.m.

2. The assembler then marks the bolts with a paint line extending over the bolt head to the block (C).

3. The final torque is then applied to the bolt leaving the line broken in the clockwise direction (D).
Image1.2.1
 
Stub Shaft Plate Inspection:

1. Refer to Image1.3.1. Any bolt that does not show a break in the marked line has not been torqued properly.

Note: Some models of borescopes will show a mirror image of the bolts. This may give a false indication of a loose bolt.
Image1.3.1
 
Cluster Gear Retainer Plate Inspection:

1. Refer to Image1.4.1. Visually inspect the bolts heads and ensure they are seated to the plate.
Image1.4.1
 
Inspection Results

1. If there are no loose bolts, reassemble the engine.

2. If loose bolts are found, please have the dealer Technical Communicator submit a request to the GDSN Service Technical requesting to escalate to tier 2 for a corrective action.
 
 

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