PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 1T1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 1T1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS

Usage:

REBE8544-00

Show/hide table

31Jul2012

U-398

A-316

D-342

O-366

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 1T1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS
3101		PI32070

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32070" 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 "PI32070" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

COMPLETION DATE	TERMINATION DATE
31Jan2013	31Jul2013

PROBLEM

Show/hide table

The 1T1223 Torque Converter Output Shaft needs to be replaced on certain 773F and 775F Off-Highway Trucks. The existing 1T1223 Output Shaft can fail and result in unexpected downtime. If the shaft fails, the truck will not move.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
773F	EED00311, 329, 335, 339, 357, 377, 380-381, 395-396, 398, 409, 415, 423, 426, 433-434, 448, 450, 463, 465, 475, 478, 484, 492, 497, 519-520, 525, 535, 540, 562, 566, 570-572, 598, 616, 638, 643-647, 658, 663, 667, 674-675, 678, 692, 717, 743, 765-766, 775, 777, 782-783, 797, 804, 816, 826, 867-869, 899-900, 908, 933, 976, 1010, 1019
775F	DLS00363, 414, 419, 431-433, 435-436, 458, 481, 488, 511-512, 542, 551, 568, 580, 607, 625-626, 632, 675, 686, 695, 698, 704, 737, 743, 775-777, 846-847, 857-858, 868, 962, 995-996, 1005, 1021-1022, 1038-1039, 1049, 1058-1059, 1061

PARTS NEEDED

Show/hide table

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 35% 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

Show/hide table

Reference attached rework procedure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

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

SERVICE CLAIM ALLOWANCES

Show/hide table

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

Show/hide table

NOTE: This is a 14.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

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

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

Show/hide table

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 1T1223 OUTPUT SHAFT ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS

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

Dear Caterpillar Product Owner:

The 1T1223 Torque Converter Output Shaft needs to be replaced on the products listed below. The existing 1T1223 Output Shaft can fail and result in unexpected downtime. 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 31Jul2012 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 31Jul2012 Service Letter

Rework Procedure

Show/hide table

Image1.1.1

Refer to the Service Manual as required.

Image1.2.1

Image1.2.2

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

Note: If this program is being applied after failure of the converter shaft, engine crankshaft endplay must be checked. Reference Specifications SENR9936 "C27 and C32 Engines for Caterpillar Built Machines". Maximum end play with used thrust plates is
0.89 mm (0.035 inch).

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".

20. Access the chassis ECM using Electronic Technician (ET) and 7X1701 Communication Adapter. Download the transmission shift matrix and send to Randy Gallinger at Gallinger_Randy_R @ CAT.com.