PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION ON CERTAIN 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION ON CERTAIN 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE6419-02

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19Jul2017

(Revised 19Sep2017)

N030
N184
N18C
N18D
N18E
R120

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION ON CERTAIN 797F OFF-HIGHWAY TRUCKS
3030 3160 3064 7750		PS45544

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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 "PS45544" 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 19Jul2017 (Revised 27Jul2017) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Jul2019

PROBLEM

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The existing 446-9392 Transmission (JH5 serial prefix) can fail on certain 797F and 797F XQ Off-Highway Trucks. If the existing transmission fails it will result in loss of drive.

AFFECTED PRODUCT

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Model	Identification Number
797F	LAJ00163, 166-168, 171-174, 189, 203, 230, 233-236, 254-262, 264, 267-269, 287, 295-296, 308, 328, 446, 460, 477, 491, 493, 508-510, 559-560, 573, 578-579, 582, 584, 596

PARTS NEEDED

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Qty	Part Number	Description
1	1U9458	PLUG AS-CONN
1	2J8163	SEAL-O RING
1	3S8035	RING-SEAL
2	4T3133	ELEMENT-HYD
1	5H8624	SEAL-O-RING
2	5M7142	SEAL-O RING
1	5P6726	RING-RETAINING
1	5P7470	CLIP-HALF SLOT
1	5P7471	CLIP-HALF TANG
1	5P7703	GROMMET
1	6F8146	SEAL-O-RING
2	6I8171	RING-SEAL
1	6V4590	SEAL-O RING
4	6V7357	BOLT-HEX HEAD
1	6V8757	RING-RETAINING
1	6Y2983	RING-SEAL
2	7C4355	CLIP
1	7X4781	SEAL-O RING
12	7X7729	WASHER-HARD
3	8E3837	RING-SEAL
12	8M4443	SEAL-O-RING
2	8M4987	SEAL-O-RING
4	8M8157	SEAL-O-RING
2	8P4617	SEAL-RING METAL
2	8P7780	RING-SEAL
2	8P8950	RING-SEAL
1	8T0070	BOLT
8	8T4121	WASHER-HARD
2	8T4136	BOLT-HEX HEAD
1	8T4172	BOLT-HEX HEAD
1	8T4183	BOLT-HEX HEAD
16	8T4186	BOLT-HEX HEAD
2	8T4192	BOLT-HEX HEAD
2	8T4195	BOLT-HEX HEAD
1	8T4196	BOLT-HEX HEAD
3	8T4223	WASHER-HARD
1	8T9527	SEAL-O-RING
1	9G8718	RING-SEAL
2	9N4146	RING-SEAL INT
2	9X7287	SEAL-O-RING
8	9X8256	WASHER
1	0336031	SEAL-O-RING
8	1124511	PIN-SPRING
4	1137764	DISC AS-FRICTION
2	1273387	BOSS
1	1284249	WASHER
1	1364992	SPACER-WELD
1	1407025	DISC-THRUST
1	1407041	RING-RETAINING
1	1407110	RING-SEAL
1	1407111	RING-SEAL
1	1486559	BEARING-SPL BALL
2	1522725	SCREEN AS
1	1548241	BEARING-BALL
2	1614512	HANDLE
2	1733272	DISC AS-FRICTION
1	1809214	NUT-HEX
10	1924744	BOLT-HEX HEAD
12	2042281	STRAP-CABLE
12	2048000	MOUNT-TIE WRAP
1	2242734	RECEPTACLE AS
1	2385082	SEAL-O-RING-STOR
4	2443114	VALVE GP-MDL -C
1	2562288	VALVE GP-MDL -C
1	2859208	GASKET
10	3011507	DISC-THRUST
2	3157798	PLATE
2	3157799	COVER
4	3445673	NUT-HEX
1	3653179	SEAL-LIP TYPE
1	3653180	SEAL-WEAR SLEEVE
3	3885576	BOSS-DRAWN ARC
1	4218019	BRACKET AS
2	4254563	VALVE GP-MDL -C
42	4447646	SPRING-WAVE
5	4471647	PIN-SPRING
7	4750296	DISC-FRICTION - As Required
1	4819789	HARNESS AS
1	4869094	PLATE AS
2	4920311	SEAL-PIP - As Required
1	5027027	COVER - SCREEN - As Required
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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The intent of this Service Letter is to provide coverage for the 446-9392, (JH5) Transmission Arrangement and failures specific to Clutch 7, 432-5469 friction disc excessive wear. The transmission can be removed before failure on a proactive basis for a mid life rebuild. The required parts recommendation (when completed on a mid life rebuild) is to allow the transmission to run another 10,000 hours before a full
zero hour rebuild is required. Exceeding this component life recommendation (18,000 component life hours) may result in transmission failures.

The parts needed list of this Product Support Program is targeted specifically for proactive mid life (Non Zero Hour) transmission rebuilds. The parts consist replacement for Clutch 1, Clutch 2, Clutch 7, train 5 coiled pins and specific bearings is to mitigate the risk of component failure for the remaining life cycle (10,000 hours). After the transmission has completed a full component life cycle (PCR), normal standard rebuild practices/component reuse will apply.

Refer to the Service Manual if/as necessary to rework the transmission. Refer to Special Instruction SEHS0335 for additional information on installing the 481-9789 Transmission Harness.

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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%
0-10000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-14000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
14001-18000 hrs, 37-48 mo	0.0%	25.0%	0.0%	0.0%	75.0%	75.0%

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NOTE: This is a 115.0-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.
Note: The 115 hours of labor is a total recommendation of 75 hours for Disassembly and Assembly of the transmission and 40 hours for transmission Removal and Install.

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