PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR AND ALTERNATOR MOUNTING GROUP ON CERTAIN 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR AND ALTERNATOR MOUNTING GROUP ON CERTAIN 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE2456-00

Show/hide table

17Dec2014

U-766

A-564

D-671

O-664

Show/hide table

Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE ALTERNATOR AND ALTERNATOR MOUNTING GROUP ON CERTAIN 797F OFF-HIGHWAY TRUCKS
1405 1154 1358		PS44608

Show/hide table

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 "PS44608" 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.

Show/hide table

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.

Show/hide table

TERMINATION DATE

31Dec2016

PROBLEM

Show/hide table

The existing alternator and alternator mounting group may fail on certain 797F off-highway trucks. If the existing alternator fails it may cause over / undercharging. If the existing guard assembly or belt tensioner fails, it could result in a thrown alternator belt and loss of electrical charge.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
797F	LAJ00141-00226, 229-310, 314-316, 318-321, 323-326, 328-507, 509-533
797F XQ	WSP00100-00129

Show/hide table

*****Group 2*****
797F	LAJ00227-00228, 311-313, 317, 322, 327, 508, 534-553

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
1	1K4649	SPACER
3	1V6645	SPACER
2	5P8245	WASHER-HARD
15	6V1820	BOLT
1	6V4248	BOLT
1	6V4249	BOLT-HEX HEAD
5	6V5839	WASHER-HARD
1	6V6317	BOLT
2	6V7673	BOLT-HEX HEAD
1	6V8149	NUT-HEX
2	6V8336	BOLT
1	6V9028	SEAL-O-RING
1	7S3916	CLIP
1	7S3919	CLIP
3	7V6571	GROMMET
1	7X7910	CLIP
1	7X7911	CLIP-HALF HOOK
1	8T0643	BOLT
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
2	8T5436	BOLT-HEX HEAD
2	8T6408	BOLT-HEX HEAD
2	1090080	SEAL-O-RING
1	1129069	BRACKET
2	1400174	BOLT-HEX HEAD
16	1984766	WASHER-HARD
1	2139397	SEAL-O-RING
1	2177742	GROMMET
1	3331207	IDLER AS
2	3427962	RING
1	3516636	TENSIONER-BELT
1	3900533	BELT
1	4207737	SUPPORT
1	4370125	ALTERNATOR GP-B
1	4478058	SUPPORT
1	4487924	PULLEY
1	4501575	TUBE AS
1	4510072	GUARD-ALT
1	4510073	GUARD AS-ALT
1	4510074	GUARD AS-ALT
1	4565132	CABLE AS
1	4575212	CABLE AS
1	COOLANT_BULK	COOLANT (as needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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	1K4649	SPACER
3	1V6645	SPACER
2	5P8245	WASHER-HARD
15	6V1820	BOLT
1	6V4248	BOLT
1	6V4249	BOLT-HEX HEAD
5	6V5839	WASHER-HARD
1	6V6317	BOLT
2	6V7673	BOLT-HEX HEAD
1	6V8149	NUT-HEX
1	6V9028	SEAL-O-RING
1	7S3916	CLIP
1	7S3919	CLIP
3	7V6571	GROMMET
1	7X7910	CLIP
1	7X7911	CLIP-HALF HOOK
1	8T0643	BOLT
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
2	8T5436	BOLT-HEX HEAD
2	8T6408	BOLT-HEX HEAD
1	1129069	BRACKET
16	1984766	WASHER-HARD
1	2177742	GROMMET
1	3331207	IDLER AS
1	3516636	TENSIONER-BELT
1	3900533	BELT
1	4478058	SUPPORT
1	4487924	PULLEY
1	4510072	GUARD-ALT
1	4510073	GUARD AS-ALT
1	4510074	GUARD AS-ALT
1	4565132	CABLE AS
1	4575212	CABLE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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

Show/hide table

Please carefully review the Service Claim Allowances Notes prior to applying this program.

Group 1 Off-highway trucks requires the replacement of the alternator mounting bracket, a new alternator, improved belt drive system and improved guard assembly, as well as the replacement of a coolant line to improve clearance for the new alternator guard assembly.

Group 2 off-highway trucks already contain the new alternator, mounting group and coolant line, so only the belt drive components and new guard-related components are needed.

Refer to Special Instruction REHS9653, "Procedure to Install the 437-0125 Charging Alternator Gp on Certain Off-Highway Truck Engines", for the installation of the alternator and drive belt systems.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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*****
0-8000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 3.0-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.
This Program can only be applied Before Failure if the Clean Fuel Module Update is being/has been installed (refer to REHS9559). The Cat service claim number for installing the Clean Fuel Module must be referenced in the claim story when this Service Letter is claimed, and must be entered into the Comments/Findings box as well. If the Clean Fuel Module is NOT being/has not been installed, then this Program can only be applied After Failure only.

Show/hide table

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*****
0-8000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-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.
This Program can only be applied Before Failure if the Clean Fuel Module Update is being/has been installed (refer to REHS9559). The Cat service claim number for installing the Clean Fuel Module must be referenced in the claim story when this Service Letter is claimed, and must be entered into the Comments/Findings box as well. If the Clean Fuel Module is NOT being/has not been installed, then this Program can only be applied After Failure only.