PRODUCT SUPPORT PROGRAM FOR REPLACING THE TRANSMISSION OUTPUT SPEED SENSOR MOUNTING BRACKET ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TRANSMISSION OUTPUT SPEED SENSOR MOUNTING BRACKET ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE5251-02

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11Jan2017

(Revised 06Apr2017)

U-27

A-19

D-19

O-21

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Before/After Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TRANSMISSION OUTPUT SPEED SENSOR MOUNTING BRACKET ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS
3175 1408 3256 3258 3281		PS45355

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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 "PS45355" 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:

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.

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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.

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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 11Jan2017 (Revised 07Feb2017) Service Letter. Changes have been made to the Parts Needed.

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TERMINATION DATE

31Jan2020

PROBLEM

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The existing transmission output speed sensor mounting bracket has the sensor mounting holes spaced in a manner that the software may not detect machine direction. This can lead to logging of the 587-7 or 673-7 diagnostic on certain 797, 797B, and 797F Off-Highway Trucks.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
797F	LAJ00141-00620
797F XQ	WSP00100-00129

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*****Group 2*****
797	5YW00193-00277
797B	JSM00123-00488

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3G1229	SHIM (as required)
1	3G1230	SHIM (as required)
1	3G1231	SHIM (as required)
1	5058896	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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	3G1229	SHIM (as required)
1	3G1230	SHIM (as required)
1	3G1231	SHIM (as required)
1	5058896	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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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****Parts Stock ****

Remove all 163-0832 transmission output sensor bracket from dealer parts stock.

Rework all 272-3338 differential and bevel gear groups in inventory with the 505-8896 transmission output sensor bracket.

****Affected Product****

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For Group 1 and 2:
Before Failure: Replace the existing 163-0832 Transmission Output Sensor Bracket with the improved 505-8896 Transmission Output Sensor Bracket at the time of component rebuild. The transmission output sensor bracket is part of the differential and bevel gear group.

For Group 1:
After Failure: The bracket may be replaced while on the machine if the machine logs a 587-7 or 673-7 diagnostic. Refer to the attached Rework Procedure to replace the transmission output speed sensor mounting bracket.

Note: The 797 and 797B machine software does not use the transmission output speed sensor to detect machine direction and will not log 587-7 and 673-7 diagnostics.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all 163-0832 transmission output sensor brackets removed from dealer parts stock.

Submit one claim for 272-3338 differential and bevel gear groups reworked in dealer parts stock. The parts listed in the Parts Needed and 1 hour are allowed for each differential and bevel gear group reworked in dealer parts stock.

****Affected Product****

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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%
*****Group 1*****
0-60000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 0.0-hour job for Group 1
The bracket may be replaced while on the machine only if the machine logs a 587-7 or 673-7 diagnostic. 2 hours of labor may be claimed if performing the update in the field.

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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%
*****Group 2*****
0-120000 hrs, 0-240 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 0.0-hour job for Group 2
Note: 797 and 797B machine software does not use the transmission output speed sensor to detect machine direction and will not log 587-7 and 673-7 diagnostics.

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

Park the machine on level ground with the park brake applied and chock the wheels. Allow sufficient time for the oil in the rear axle housing to cool.

Image1.2.1

Place a drip pan under the COLD differential to catch any oil. Remove the rear axle housing cover to gain access to the Transmission Output Speed (TOS) sensors and mounting bracket.

Image1.4.1

Remove both TOS Speed Sensors, shims and the TOS Bracket mounting bolts.

NOTE - The shims are very thin and are likely to be left in the old bracket hole.

Use a small thin pry bar to separate the bracket away from the axle housing.

Image1.6.1

Use a punch to remove the alignment pins from the old bracket.

Image1.8.1

Install the alignment pins into the new bracket. Make certain that the chamfered side is facing towards the axle housing.

Image1.10.1

Install the TOS Bracket onto the axle housing and tighten the bolts to 240 +/- 40Nm (177 +/- 29.5 Ft lbs)

Install the shims and both TOS sensors onto the bracket. Tighten the sensor to 37 +/- 4 Nm

Image1.13.1

Verify that the gap between the sensor and the target gear is 1mm +/- 0.5mm (0.039" +/- 0.02")

Image1.15.1

Image1.15.2

Verify that the wiring from the Transmission ECM to each sensor is correct per the schematic. To verify the wiring is correct, use a jumper wire to ground pin 1 (E901 - XF12) at TOS sensor number 1 connector. At the transmission ECM, verify that pin 1 is grounded. Repeat this procedure for all four pins.

TOS #1 Sensor:

Pin 1 E901 (Green) J1-7
Pin 2 E900 (White) J1-6

TOS #2 Sensor:

Pin 1 E907 (Grey) J1-9
Pin 2 E906 (Orange) J1-8