PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW ACCESSORY DRIVE GROUP AND DRIVE SHAFT ON CERTAIN 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW ACCESSORY DRIVE GROUP AND DRIVE SHAFT ON CERTAIN 793D OFF-HIGHWAY TRUCKS

Usage:

REBE3320-01

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05May2008

(Revised 02Jul2008)

U-230

A-186

D-182

O-206

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW ACCESSORY DRIVE GROUP AND DRIVE SHAFT ON CERTAIN 793D OFF-HIGHWAY TRUCKS
3253 7153		PI31492

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31492" 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 "PI31492" 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:

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 02May2008 Service Letter. Changes have been made to Parts Needed. 5R7137 Sealing-Washer quantity changed from 2 to 4. 6V-3823 Bolts added to Grp 1 and Grp 2. Gasket added for flywheel housing cam cover.

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COMPLETION DATE	TERMINATION DATE
30Nov2008	31May2009

PROBLEM

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The accessory drive sleeve bearing needs to be updated on certain the 793D Off-Highway Trucks. The existing sleeve bearing can seize and fail from lack of lube. The drive shaft spider bearing can fail from overload.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
793D	FDB00105-00496

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*****Group 2*****
793D	FDB00497-00580

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*****Group 3*****
793D	FDB00581-00752

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2K7471	LOCKNUT
1	3F5792	SEAL-O RING
1	3J5389	PLUG-PIPE
1	3K5234	WASHER-HARD
4	5R7137	WASHER-SEALING
8	6V3823	BOLT
1	7N4320	GASKET
1	1095721	SEAL-DIRT
1	1095722	SEAL-LIP TYPE
1	2010439	SEAL-LIP TYPE
1	2888960	ADAPTER AS
1	3003304	YOKE AS
1	3003307	JOINT GP
1	3004657	GUARD
1	3004658	PLATE AS
1	3015186	YOKE
1	3150633	SHAFT AS
1	3168654	CAGE AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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	2K7471	LOCKNUT
1	3F5792	SEAL-O RING
1	3J5389	PLUG-PIPE
1	3K5234	WASHER-HARD
4	5R7137	WASHER-SEALING
8	6V3823	BOLT
1	7N4320	GASKET
1	1095721	SEAL-DIRT
1	1095722	SEAL-LIP TYPE
1	2010439	SEAL-LIP TYPE
1	2888960	ADAPTER AS
1	3003304	YOKE AS
1	3003307	JOINT GP
1	3015186	YOKE
1	3150633	SHAFT AS
1	3168654	CAGE AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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	2K7471	LOCKNUT
1	3F5792	SEAL-O RING
1	3J5389	PLUG-PIPE
1	3K5234	WASHER-HARD
4	5R7137	WASHER-SEALING
1	7N4320	GASKET
1	1095721	SEAL-DIRT
1	1095722	SEAL-LIP TYPE
1	2888960	ADAPTER AS
1	3015186	YOKE
1	3150633	SHAFT AS
1	3168654	CAGE AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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See the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 3

PARTS DISPOSITION

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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW ACCESSORY DRIVE GROUP AND DRIVE SHAFT ON CERTAIN 793D OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 793D Off-Highway Trucks

Dear Caterpillar Product Owner:

The accessory drive (PTO) needs to be updated on the products listed below. The existing accessory drive sleeve bearing can fail from lack of lube. The accessory drive shaft needs to be updated. The drive shaft spider bearing can fail from overload. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 05May2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 05May2008 Service Letter

Rework Procedure

NOTE: Instructions are S/N range specific. Read instructions before commencing work. S/N ranges below do not necessarily coincide with the Group Ranges. Use the S/N instructions that apply to the truck being updated.

FDB00001-00496
Remove the (14) 293-4571 Guard As. (engine side) The guard will not be reused. Save the 3 ? 5M3062 Bolts and 3 ? 9L9132 Washers for reassembly.

FDB00497-00580
Remove the (14) 300-4657 Guard As. (engine side). Save the (14) 300-4657 Guard As., 3 ? 5M3062 Bolts and 3 ? 9L9132 Washers for reassembly.

FDB00001-00580
Remove the (15) 250-8613 or (15) 293-4572 Guard As. (pump side) Save the 3 ? 8T4139 Bolts and 3 ? 8T4223 Washers and 250-8613 or 293-4572 Guard As. for reassembly.

FBD00581 and UP
Removal of the (15) 250-8613 or (15) 293-4572 Guard As. is NOT required.

Image1.1.1

FDB00001-00580
Remove the 276-3210 Shaft Gp-Drive-Pump.

FBD00581 and UP
Remove the front 9P-0356 Bearing-Spider of the 300-3307 Joint Gp. from the (1) 301-5186 Yoke.

FDB00001-00580
Remove the (1) 5T1009 Yoke. (will a need new 2K-7471 Locknut (1-14-THD) and 3K-5234 Washer-Hard).

FBD00581 and UP
Remove the (1) 301-5186 Yoke and save for reinstallation if not damaged during removal. (will a need new 2K-7471 Locknut (1-14-THD) and 3K-5234 Washer-Hard).

Image1.2.1

FBD00001 and UP
Remove the (7) 282-9627 Hose As. and related clips. (need a 3J5389 Plug in oil adapter).
Install the (8) 3J5389 Plug into 2W-7226 Adapter (Turbo) where the 282-9627 Hose As. was removed.
Remove the (16) 285-8440 Plate As. Save the 3 - 1F-7958 Nut-Full (1/2-13-THD) and 3 - 5P-8245 Washer-Hard for reassembly.
Remove the (2) 282-3785 Adapter As. and (3) 283-0746 Washer-Thrust. Save the 4 - 1F-7958 Nut-Full (1/2-13-THD) and 4 - 5P-8245 Washer-Hard for reassembly.
Remove the (4) 137-8237 Shaft As. Save the 16 - 5P-2546 Bolts for reassembly.
Remove the (5) 7N-8525 Washer-Thrust and the (6) 141-7120 Cage As. Save the 2 -1A-1460 Bolts and 2 - 5P-8245 Washers for reassembly. (will need 2 new 5R-7137 Washer-Sealing for reassembly).

Image1.3.1

FDB00001-00580
Remove the (13) 276- 7237 Yoke Assembly from the shaft.
Remove the (12) 201-0439 Seal from the (17) 271-0439 Pump Gp. and install a new (12) 201-0439 Seal into the 271-0439 Pump Gp.
Slide the new (13) 300-3304 Yoke Assembly onto the (17) 271-0439 Pump Gp shaft.

FBD00001 and UP
Install the (6) 316-8654 Cage As. using the saved 2 -1A-1460 Bolts and 2 - 5P-8245 Washers and 2 new 5R-7137 Washer-Sealing.
Install the (5) 315-0633 Shaft As. using the saved 16 - 5P-2546 Bolts.
Install the (9) 109-5722 Seal-Lip and (10) 109-5721 Seal-Dust into the (2) 288-2860 Adapter As.
Install the (11) 3F5792 Seal-Oring onto the (2) 288-2860 Adapter As.
Install the (2) 288-8960 Adapter As. using the saved 4 - 1F-7958 Nut-Full (1/2-13-THD) and 4 - 5P-8245 Washer-Hard.

NOTE: The (2) 288-8960 Adapter As. must be installed with the arrow in the up position or failure of the bearing may occur.

Install the (16) 300-4658 Plate As. using 3 - 1F-7958 Nut-Full (1/2-13-THD) and 3 - 5P-8245 Washer-Hard
Install the (1) 301-5186 Yoke using a new 2K-7471 Locknut (1-14-THD) and 3K-5234 Washer-Hard). Tighten the locknut to a torque of 750 +/- 20 N-m.

Install the 300-3307 Joint Gp. (includes 1 - 300-9597 Shaft As., 2 ? 9P-0356 Bearing-Spider and 16 ? 6V-3823 Bolts [8 installed and 8 loose]) with the 8-6V-3823 Bolts (loose) that were supplied with the 300-3307 Joint Gp. Tighten to a torque of 120 +/- 20 N-m.

Install the (14) 300-4657 Guard As. using the 3 ? 5M3062 Bolts and 3 ? 9L9132 Washers saved from disassembly.
Install the (15) 250-8613 or (15) 293-4572 Guard As. (pump side) using the 3 ? 8T4139 Bolts and 3 ? 8T4223 Washers saved from disassembly.