PRODUCT SUPPORT PROGRAM FOR REPLACING THE 140-6125 FRICTION DISCS IN CLUTCHES #2, 3 AND 4 ON CERTAIN 797 OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 140-6125 FRICTION DISCS IN CLUTCHES #2, 3 AND 4 ON CERTAIN 797 OFF-HIGHWAY TRUCKS

Usage:

TEBE4328-01

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08Mar2016

(Revised 07Jul2016)

R120

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 140-6125 FRICTION DISCS IN CLUTCHES #2, 3 AND 4 ON CERTAIN 797 OFF-HIGHWAY TRUCKS
3187 3160		PS45016

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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 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 "PS45016" 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.

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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 08Mar2016 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Mar2018

PROBLEM

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The splines in the existing 140-6125 Friction Discs can wear on Clutch #2, 3 and 4 on certain 797 Off-Highway Trucks. If the splines in the existing 140-6125 Friction Discs wear, it will leave Clutch #2 inoperable.

AFFECTED PRODUCT

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Model	Identification Number
797F	LAJ00148-00150, 158-182, 185-187, 216-221, 230, 233-236, 247-250, 256-261, 263, 265, 397, 406, 408, 411, 414-415, 423, 425-427, 433, 435-438, 467, 471-473, 495-501

PARTS NEEDED

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Qty	Part Number	Description
5	1J9671	SEAL-O-RING
4	1S2174	SEAL-O RING
10	1S9110	BEARING-NEEDLE
1	2H3934	SEAL-O RING
1	2M3889	RING-SEAL
8	2M9780	SEAL-O-RING-STOR
4	2S4078	SEAL-O-RING
4	3D2824	SEAL-O-RING-STOR
34	3J1907	SEAL-O-RING-STOR
3	3J7354	SEAL-O-RING-STOR
6	3K0360	SEAL-O-RING
2	3S8035	RING-SEAL
1	3S8109	PIN-SPRING
1	3T8729	BEARING-SLEEVE
2	4J7533	SEAL-O-RING-STOR
10	4K1388	SEAL-O-RING-STOR
1	4L7711	SEAL-O RING
1	4S8541	DOWEL
1	5H3182	PIN-SPRING
1	5H8624	SEAL-O-RING
1	5H8848	SEAL-O RING
3	5H9839	PIN-SPRING
2	5M7142	SEAL-O RING
2	5P7703	GROMMET
5	6F6672	SEAL-O RING
2	6I8171	RING-SEAL
20	6I9809	BEARING-NEEDLE
1	6J2680	SEAL-O-RING
1	6K6307	SEAL-O-RING
14	6V0852	CAP-DUST
20	6V4365	SEAL-O-RING
1	7F8268	SEAL-O RING
2	7J0204	SEAL-O-RING
13	7M8485	SEAL-O-RING-STOR
1	7T2457	RING-TORIC
1	7X1547	SEAL-O-RING
1	7X9372	SEAL-O RING
1	8C3080	SEAL-O RING
1	8C3447	CAP-DUST
3	8E3837	RING-SEAL
1	8F6711	SEAL-O RING
1	8F8861	SEAL-O-RING
2	8M4435	SEAL-O-RING
14	8M4443	SEAL-O-RING
2	8M4445	SEAL-O RING
3	8M4987	SEAL-O-RING
2	8M5252	SEAL-O RING
1	8M5253	SEAL-O-RING
4	8M5254	SEAL-O-RING
4	8M8157	SEAL-O-RING
2	8P4617	SEAL-RING METAL
2	8P7780	RING-SEAL
2	8P8950	RING-SEAL
2	9G8718	RING-SEAL
2	9N4146	RING-SEAL INT
1	0068350	SEAL-O-RING
1	1004083	SEAL KIT
1	1046730	GASKET
23	1124511	PIN-SPRING
1	1407020	RING-SEAL
1	1407025	DISC-THRUST
1	1407028	BEARING-SLEEVE
3	1407076	RING-SEAL
1	1407097	RING-SEAL
1	1407098	RING-SEAL
2	1407110	RING-SEAL
2	1407111	RING-SEAL
10	1407130	DISC-THRUST
1	1486559	BEARING-SPL BALL
8	1495614	BEARING
1	1536709	GASKET-ACCESS
1	1536721	GASKET-TOP COVER
1	1548237	BEARING-BALL
2	1548238	BEARING-BALL
1	1548240	BEARING-BALL
1	1548241	BEARING-BALL
2	1565850	RING-SEAL
1	1565851	RING-SEAL
1	1614511	SEAL-O-RING
10	1733272	DISC AS-FRICTION
8	1790857	DISC-THRUST
30	1790858	DISC-THRUST
1	1889803	RING-SEAL
10	1929969	BEARING
1	1985373	BRG-SPL BALL
10	2745106	BEARING-SPL CAGE
8	2837997	BEARING-RLR AS
8	2859200	DISC-THRUST
10	3011507	DISC-THRUST
1	3653179	SEAL-LIP TYPE
1	3653180	SEAL-WEAR SLEEVE
1	3759921	BEARING-SPL BALL
78	4447646	SPRING-WAVE
24	4469233	SPRING-WAVE
10	4471647	PIN-SPRING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 19% 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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If the transmission has failed due to failed Clutch #2 splines, replace Clutches #2, 3 and 4 with new 173-3272 Friction Discs as referenced in previous Service Magazine SEPD2042 (published August 26, 2015).

Refer to the 797F Planetary Disassembly and Assemble Procedure (KENR8372).

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SERVICE CLAIM ALLOWANCES

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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%
0-7000 hrs, 0-84 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
7001-14000 hrs, 85-168 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
14001-18000 hrs, 169-216 mo	0.0%	25.0%	0.0%	0.0%	75.0%	75.0%

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NOTE: This is a 100.0-hour job 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.

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