PRODUCT IMPROVEMENT PROGRAM FOR REWORKING TRANSMISSIONS OF CERTAIN 815F COMPACTORS; AND ON CERTAIN 966G II AND 972G II WHEEL LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING TRANSMISSIONS OF CERTAIN 815F COMPACTORS; AND ON CERTAIN 966G II AND 972G II WHEEL LOADERS

Usage:

SEBE9171

May 8, 2005
U-145
A-108

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING TRANSMISSIONS OF CERTAIN 815F COMPACTORS; AND ON CERTAIN 966G II AND 972G II WHEEL LOADERS
3054 3030		PI30809

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30809" 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 "PI30809" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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COMPLETION DATE	TERMINATION DATE
November 30, 2005	May 31, 2006

PROBLEM

The 155-5571 Plates and 155-5572 Plates were installed incorrectly at assembly on certain 815F Compactors; and on certain 966G II and 972G II Wheel Loaders. This may result in premature friction material wear in the direction clutch and/or breakage of the 1155572/">115-5572 Plate-Clutch. The 115-5571 and 1155572/">115-5572 Plate-Clutches need to removed and reinstalled in the proper location.

AFFECTED PRODUCT

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Model	Identification Number
815F	BKL721-724, 727-742
966G II	ANT308-311, 313-320
966G II	ANZ1225-1263
972G II	ANY407, 409, 410
972G II	AWP506-525, 527-533, 535

PARTS NEEDED

Dealers will need to order parts for this Program.

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Quantity	Part Number	Description
Group 1 - Less Than 5 Hours/Not Shifted Under Load
4	3H0107	SEAL-O RING
1	8M5010	SEAL-O RING
1	8M5255	SEAL-O RING
1	9M5024	SEAL-O RING
1	3S9896	SEAL-O-RING
4	4S5924	SEAL-O RING

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Quantity	Part Number	Description
Group 2 - More Than 5 Hours/Shifted Under Load/Moved Material
4	3H0107	SEAL-O RING
1	8M5010	SEAL-O RING
1	8M5255	SEAL-O RING
1	9M5024	SEAL-O RING
*8	9P7390	DISC AS-FRIC
1	3S9896	SEAL-O-RING
4	4S5924	SEAL-O RING
*8	1155572	PLATE-CLUTCH
* if required

ACTION REQUIRED

See the attached procedure.

OWNER NOTIFICATION

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.
100%	58	0	0	0	0
NOTE: This is a 58-hour job.
NOTE: U.S. and Canadian Dealers Only - This program does not qualify for a Type 2 SIMS Report.
NOTE: If 9P7390 Disc Assemblies or 1155572/">115-5572 Plates were replaced record the machine hours, type of application, and location installed in the "additional comments" section of the warranty claim.

PARTS DISPOSITION

NOTE: All dealers are to make sure the outside of the shipping container is marked PI30809. Return all 9P7390 Disc Assemblies and 1155572/">115-5572 Plates that were replaced and a copy of the claim to:

Caterpillar Inc.

Attn: Rick Walker PI30809
Service Claims Room
8201 N. University
Peoria, IL 61615 MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING TRANSMISSIONS OF CERTAIN 815F COMPACTORS; AND ON CERTAIN 966G II AND 972G II WHEEL LOADERS MODELS INVOLVED - 815F COMPACTORS; AND 966G II AND 972G II WHEEL LOADERS

Dear Caterpillar Product Owner:

The 155-5571 Plates and 155-5572 Plates were installed incorrectly at assembly on the products listed below. This may result in premature friction material wear in the direction clutch and/or breakage of the 1155572/">115-5572 Plate-Clutch. The 115-5571 and 1155572/">115-5572 Plate-Clutches need to removed and reinstalled in the proper location.

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 May 8, 2005 when scheduling this service. You will not be charged for the service performed.

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 May 8, 2005 Service Letter

REWORK PROCEDURE

ACTION REQUIRED

(Group 1 - Less Than 5 Hours/Not Shifted Under Load)

Using Service Manual procedures, remove and disassemble the planetary group.

Take all of the 1155572/">115-5572 Plates from the direction clutch (forward and reverse) and install them in the speed clutches (1st, 3rd and 4th). Take the 115-5571 Plates from the speed clutches and install them in the direction clutches.

Reassemble the planetary group and transmission arrangement, using the Seal-O-Rings listed above.

Note: No other replacement parts are required during the rework. ACTION REQUIRED

(Group 2 - More Than 5 Hours/Shifted Under Load/Moved Material)

Using Service Manual procedures, remove and disassemble the planetary group.

Inspect the 1155572/">115-5572 Plates (incorrectly installed in the direction clutch). Use the table below to determine if the 1155572/">115-5572 Plates need to be replaced. If 1 of the 1155572/">115-5572 plates fail the inspection criteria, replace all 4 Plates used in that clutch.

Inspect the 9P7390 Disc Assemblies (correctly installed in the direction clutch). Use the table below to determine if the 9P7390 Disc Assemblies need to be replaced. If 1 of the 9P7390 Disc Assemblies fail the inspection criteria, replace all 4 Disc Assemblies used in that clutch.

NOTE: All 9P7390 Disc Assemblies and 1155572/">115-5572 Plates that are replaced need to be returned for further analysis. Record the machine hours, type of application, and location installed. This information must be entered into the "additional comments" section of the warranty claim.