PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR STARTER DRIVE ON CERTAIN 785C, 789C, 793C, 797B OFF-HIGHWAY TRUCKS, 994D, AND 994F WHEEL LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR STARTER DRIVE ON CERTAIN 785C, 789C, 793C, 797B OFF-HIGHWAY TRUCKS, 994D, AND 994F WHEEL LOADERS

Usage:

SEBE9436

January 2, 2006
U-2
A-2
D-2
O-3

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*After failure only* *Parts stock action needed*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE AIR STARTER DRIVE ON CERTAIN 785C, 789C, 793C, 797B OFF-HIGHWAY TRUCKS, 994D, AND 994F WHEEL LOADERS
1451		PS51063

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51063" as the Part number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

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.

TERMINATION DATE

January 31, 2007

PROBLEM

Rubber cushion in starter drive is not compatible with oil. When exposed to hot oil the rubber breaks down, fouling the drive and impeding the travel of the drive pinion into the starter. This failure keeps the engine from starting.

AFFECTED PRODUCT

****Group 1****

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Model	Identification Number
797B	JSM183, 186, 188-189, 195-202

****Group 2****

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Model	Identification Number
785C	APX481, 510, 521, 526-527, 531, 538-541, 616-617, 646, 650-652, 671-673, 684
789C	2BW690, 693, 705, 750-753, 765-768, 777-778, 801-803, 828, 836-838, 875
793C	ATY718-721, 732-733, 736-737, 752-753 FDB105-110 ATY783-784, 786-799, 846-848, 859, 861-862, 866-872, 887-888, 893, 895-896, 905-906, 916-920, 929-930
994D	3TZ312, 316, 320, 323-326, 328, 334-336
994F	44200150, 153-156, 165-166

PARTS NEEDED

****Group 1****

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Qty	Part Number	Description
2	2780513	STARTER DRIVE

****Group 2****

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Qty	Part Number	Description
1	2780513	STARTER DRIVE

ACTION REQUIRED

***** Parts Stock *****

Remove all 205-4826 Starter Drives that have date codes from April 2004 to April 2005 (D04 to D05) as shown in the second photo from stock. Any starters with an "M" after the serial number or a starter drive with a "-2" (as shown immediately below) are good and should not be reworked.

Illustration 1

Illustration 2

***** Affected Product *****

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all 205-4826 Starter Drives that are removed from 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
0-10000	100%	4.0	0	0	0	0
NOTE: This is a 4.0 hr job.

PARTS DISPOSITION

***** U.S. and Canadian Dealers *****

Return all 205-4826 Starter Drives that are removed from parts stock and a copy of the claim to:

Caterpillar Inc.
Attn: Supplier Recovery
Service Claims Room
8201 N. University
Peoria, IL 61615

*****All Other Dealers*****

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

Attach. (1-Rework Procedure)

Rework Procedure

Mark position of drive pinion opening relative to gearbox housing for reference during re-assembly.

Illustration 1

Remove the 12 screws and pull drive housing from gearbox housing. If drive housing is too tight, tap it with a mallet to loosen.

Illustration 2

Remove o-ring from drive housing.

Illustration 3

Remove return spring and pull drive from carrier shaft assembly.

Illustration 4

Remove split rings from drive assembly.

Illustration 5

Drive Installation:

Apply a liberal amount of 1P0808 multipurpose grease or equivalent to interior wall of drive housing and split rings.

Illustration 6

Install split rings onto new drive assembly.
Install new drive assembly onto carrier shaft and place return spring over drive assembly.
Lubricate new o-ring with Parker o-ring lubricant or equivalent and install o-ring onto drive housing.
Install drive housing onto gearbox housing.
Secure drive housing to gearbox assembly with twelve (12) new screws from drive kit. Torque screws tol 50 in-lbs.