PRODUCT SUPPORT PROGRAM FOR REPLACING THE RETARDING GRID FAN BLADE ASSEMBLY ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RETARDING GRID FAN BLADE ASSEMBLY ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS

Usage:

TEBE8428-00

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14Nov2018

R120
R12Z

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Before/After (Limited distribution) Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RETARDING GRID FAN BLADE ASSEMBLY ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS
425R 1627 1321 1603 1469 5703		PS46060

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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 "PS46060" 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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TERMINATION DATE

31May2019

PROBLEM

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Certain 795F AC Off-Highway Trucks operating at altitudes above 9,000ft (2743m) may experience failures of the retarding grid fan blades in the retarding grid motor fan assembly.

AFFECTED PRODUCT

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Model	Identification Number
795F AC	ERM00169, 205, 264, 270-272, 274-275

PARTS NEEDED

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Qty	Part Number	Description
6	3B4508	LOCKWASHER (Before Failure Only)
6	5P2424	BOLT (Before Failure Only)
1	4526805	RETARDER GP-ELEC (After Failure Only)
1	5400971	BLADE AS (Before Failure Only)
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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****Parts Stock ****

Rework Motor As. 349-7828, Motor As. 483-2122, Retard Gp. 293-2208, and Retarder Gp. 452-6805 in dealer parts stock. Replace the existing fan blade assembly with the 540-0971 fan blade assembly.

****Affected Product****

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Rework the retarder grid to replace the 434-5144 fan blade assembly with a 540-0971 fan blade assembly.

The local dealer is to develop a component exchange strategy to remove/replace the retarder grid to reduce machine downtime.

Dealer to perform the retarder grid rework at dealer repair facility outside of the customer mine. Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all Motor As. 349-7828, Motor As. 483-2122, Retard Gp. 293-2208, and Retarder Gp. 452-6805 reworked in dealer parts stock. Up to 8 hours is allowed for each Motor As. reworked in dealer parts stock. Up to 36 hours is allowed for each Retarder Gp reworked in dealer parts stock. Six 3B-4508 Lockwashers, six 5P-2424 Bolts, and one 540-0971 Blade As. are allowed for each Motor As. or Retarder Gp. 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%
0-30000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 36.0-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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PARTS DISPOSITION

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****Parts Stock****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

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****Affected Product****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

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Rework Procedure

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ON SITE REWORK PROCEDURE

Refer to Disassembly and Assembly, KENR8727 for removal and installation instructions for the grid, as required, in order to complete the Rework Procedure.
The retarder is mounted onto the right hand platform.

OFF SITE REWORK PROCEDURE

Refer to Disassembly and Assembly, KENR8727, "Electric Retarder - Disassemble - Grid Assembly", and "Electric Retarder - Assemble - Grid Assembly"

The electric retarder section with a "Date updated" of August 1, 2017 or later will include full details for removing the fan blade assembly from the electric retarder.

1.Using a Permanent Pen, mark the element locations. Refer to the Service Manual if/as necessary and Follow the Disassembly Instructions in KENR8727 to remove all four Resistor Elements and the Intake Screen. (Image 1.2.1)

Image1.2.1

2. With the resistors removed, remove the bolts and the retaining plate from the top of the fan assembly.(Image 1.3.1)

3.Install the three guide pins into the holes as shown below.(Image 1.3.2)

4.Use fabric lifting straps that are rated to a minimum of 500 lbs, to lift the fan assembly off of the motor. Make certain that the fan is kept level and square to the rotor as to not make contact with the sides of the rotor coils. (Image 1.3.3)

Image1.3.1

Image1.3.2

Image1.3.3

5.Clean the stator assembly with compressed air. (Image 1.4.1)

6.Clean the top of the fan mounting surface with a soft cloth. (Image 1.4.2)

7.Clean the top and bottom of the mounting surface of the new fan assembly.

Image1.4.1

Image1.4.2

Image1.4.3

8.Carefully lower the new fan assembly over the guide pins and onto the stator. Make certain that the fan is kept level and square to the rotor as to not make contact with the sides of the rotor coils. (Image 1.5.1)

9.Remove the guide pins. (Image 1.5.2)

10.Apply a thin layer of RTV silicone around the bolt holes to prevent any moisture from entering the front of the fan assembly. (Image 1.5.3)

Image1.5.1

Image1.5.2

Image1.5.3

11.Install the retaining plate. (Image 1.6.1)

12.Place a thin layer of RTV silicone on the shank of the new retaining bolts and install. (Image 1.6.2)

13.Tighten the bolts in an crisscross pattern to 82 ft lbs. (Image 1.6.3)