PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 1T-1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 1T-1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS

Usage:

REBE6518-00

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09Dec2010

U-491

A-404

D-430

O-432

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 1T-1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS
3101		PI31828

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31828" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31828" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE	TERMINATION DATE
30Jun2011	31Dec2011

PROBLEM

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The 1T-1223 Output Shaft needs to be replaced on certain 773F and 775F Off-Highway Trucks. The existing 1T-1223 Output Shaft can fail. If the shaft fails, the truck will not move.

AFFECTED PRODUCT

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Model	Identification Number
773F	EED00273-00274, 277, 280, 283-285, 293, 299, 304, 310, 319-320, 327, 336, 342-343, 345, 354-356, 360, 367, 370, 376, 386-387, 389-394, 404, 407-408, 413, 422, 429, 441-442, 445-446, 455-456, 458-459, 462, 464, 467-469, 474, 479-480, 482, 486, 503, 522, 528, 533, 542-543, 548-549, 558, 573-574, 578-580, 585-586, 599-600, 603-606, 609, 615, 618-620, 655-657, 672-673, 682-683, 686-687, 702-703, 715-716, 721, 749-750, 770-773, 785-786, 789-792, 812, 824-825, 831-832, 914-915
775F	DLS00275, 278, 283-285, 291-292, 299-301, 303, 312-313, 320, 322-324, 326, 333-334, 341-343, 345, 348, 352, 362, 364-365, 372, 374, 378, 383-391, 395-396, 400-402, 404, 407, 415-416, 420-421, 429-430, 443, 445, 451, 475-476, 479, 486, 489, 507, 523, 525, 528, 531, 533, 561, 567, 584, 587, 593-594, 600, 621, 628-630, 649, 662-663, 665, 676, 693, 712, 715, 719, 721-722, 751, 802, 825, 861, 863

PARTS NEEDED

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Qty	Part Number	Description
2	0T0768	BOLT
1	1L7205	BEARING-BALL
1	1T0136	SEAL-O RING
3	1T1011	SHIM
3	1T1012	SHIM
1	1T1222	GASKET
1	4H6730	SEAL-O RING
2	6Y5888	RING-SEAL
2	8M4433	SEAL-O-RING
1	1395802	SEAL LIP-TYPE
1	3520384	SHAFT-OUTPUT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

NOTE: This is a 14.0-hour job

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 1T-1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 773F AND 775F OFF-HIGHWAY TRUCKS

Dear Caterpillar Product Owner:

The 1T-1223 Output Shaft needs to be replaced on the products listed below. The existing 1T-1223 Output Shaft can fail. If the shaft fails, the truck will not move. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 09Dec2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 09Dec2010 Service Letter

Rework Procedure

Image1.1.1

Refer to Disassembly and Assembly Manual, RENR8279, "Torque Converter ? Remove" and "Torque Converter - Install".

Image1.2.1

1. Refer to Disassembly and Assembly Manual, RENR8279, "Torque Converter ? Remove" to remove the torque converter assembly from the vehicle.

Image1.3.1

2. Remove six bolts (1) then remove pilot housing (2).

Image1.4.1

3. Remove two bolts (3) then remove retainer (4) and washer (8).

Image1.5.1

4. Remove retainer bolt (6), retainer (7), yoke flange (5), seal (9) and shims (10). Seal and shims not shown. Seal (9) will be replaced later.

Image1.6.1

5. Remove eight bolts (11), distributor (12), and gasket (13) not shown. Gasket will be replaced later with new.

Image1.7.1

6. Remove converter shaft assembly (17).

Image1.8.1

7. Remove two seals (15) from seal carrier (16). Seals (15) will be replaced later with new.

Image1.9.1

8. Place shaft assembly in appropriate support tooling and press to remove seal carrier (16) and bearing (14). Bearing will be replaced later with new.

Image1.10.1

9. Place new bearing (14) and seal carrier (16) in 300 F oven for 20 minutes. Install heated new bearing (14) and seal carrier (16) on new shaft (17). Allow assembly to cool.

Image1.11.1

10. Wrap new seals (15) in preparation for installation.

Image1.12.1

Image1.12.2

11. Install new seals (15) onto seal carrier (16). Lube seals with assembly aid lubricant.

Image1.13.1

12. Install converter shaft assembly (17).

Image1.14.1

13. Install washer (8), retainer (4), and two new 0T0768 bolts (3). Tighten the bolts to a torque of 80+/-10 N.m (59 +/- 7 lb ft).

Image1.15.1

14. Install new seal (18) with tooling "C".

Image1.16.1

15. Install tooling "A". Install new gasket (13) not shown and distributor (12).

Image1.17.1

16. Install eight bolts (11) and tighten bolts to a torque of 50+/-7 N.m (35 +/- 5 lb ft).

Image1.18.1

17. Lubricate seal then install yoke flange (5).

Image1.19.1

18. Use Tooling (B) (not shown) to measure the distance between the end of output shaft (17) and the shoulder on flange (5). Record this Dimension as Dimension (W). Note: The thickness of the shims to use must have a total thickness of 0.13 to 0.25 mm (0.005 to 0.010 inch) less than the Dimension (W).

Image1.20.1

19. Install new O-ring seal (9), shims (10) as calculated in previous step, retainer (7), and retainer bolt (6). Tighten bolt (6) to a torque of 240 +/- 25 N.m (175 +/- 18 lb ft).
End By: Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Install".