PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN BELT TIGHTENER BEARINGS ON CERTAIN 785G OFF-HIGHWAY TRUCKS Caterpillar


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PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN BELT TIGHTENER BEARINGS ON CERTAIN 785G OFF-HIGHWAY TRUCKS [UEBE1350]
BASIC ENGINE
BELT TIGHTENER GP
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN BELT TIGHTENER BEARINGS ON CERTAIN 785G OFF-HIGHWAY TRUCKS
UEBE1350-00

09Oct2020


U-601
A-495
D-566
O-555

 

Priority

  
  

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN BELT TIGHTENER BEARINGS ON CERTAIN 785G OFF-HIGHWAY TRUCKS

1358
PI33224
NOTE:

AVSpare’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 AVSpare.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI33224" 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 "PI33224" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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 AVSpare product analyst.


COMPLETION DATE

TERMINATION DATE

30Apr2021 31Oct2021

PROBLEM

The existing bearings can fail on certain 785G Off-Highway Trucks. If the existing bearing fails it may cause resultant damage to the radiator and other components.

AFFECTED PRODUCT

Model Identification Number
785G  RTL00100, 104-105, 110-114
785G OEM  TRG00100

PARTS NEEDED

Qty

Part Number Description
1 0S1594 BOLT
1 0S1595 BOLT
4 0S1617 BOLT
1 0S1621 BOLT
1 1F7958 NUT-HEX
1 2M2742 PLATE-RETAINER
1 2N8374 GASKET
2 3B4617 COTTER
1 3B6552 ADAPTER-ELBOW
1 3B8686 ADAPTER-ELBOW
1 4D1326 LOCKWASHER
1 5M2057 SEAL-O-RING
6 5P8245 WASHER-HARD
1 5S2106 SEAL-LIP TYPE
1 6U1989 FITTING-RELIEF
1 7W8460 WASHER-RETAINING
2 8B1419 PIN-CLEVIS
2 8C7510 CLIP
2 8H9789 BEARING-BALL
1 8N9409 COVER
1 8N9410 SPACER
1 8T4896 WASHER-HARD
4 9M1974 WASHER-HARD
2 1653933 BOLT-HEX HEAD
2 2314471 BOLT-HEX HEAD
1 2428023 BRACKET
1 2923198 WASHER-HARD
1 4250545 BRACKET AS
1 5846610 PULLEY
1 5846612 SPACER
1 5846616 ARM AS
1 5861409 HOSE AS-GREASE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 42% 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

Replace sealed bearing assembly with a greaseable bearing. Refer to the attached Rework Procedure.

OWNER NOTIFIAVSION

Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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

 NOTE: This is a 4.0-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.
 
 
 
EXAMPLE COPY OF OWNER NOTIFIAVSION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN BELT TIGHTENER BEARINGS

MODELS INVOLVED - CERTAIN 785G OFF-HIGHWAY TRUCKS

Dear Cat Product Owner:


The fan belt tightener needs to be reworked on the products listed below. The existing bearings can lose lubrication and fail. You will not be charged for the service performed.

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

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 09Oct2020 when scheduling this service.

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



AVSpare Inc.

Identification #(s)



Attached to 09Oct2020 Service Letter


Rework Procedure


 
Refer to Operation and Maintenance Manual, and Disassembly and Assembly.

Tooling:
(A) 1P-0500 Driver Group

1. Remove Belts (Image 1.1.1) then disconnect tightener springs from arm (Image 1.1.2).
Note: Tightener springs will be reconnected to new arm. Loosening hardware on 431-4097 bracket after belts are removed may aid in spring removal from tightener arm.

2. Remove bolt 0S-1594, washers and plate (Image 1.1.3).

3. Remove tightener arm assembly (Image 1.1.4).
Note: The new tightener assembly can be pre-assembled, and ready for immediate installation before removing old tightener assembly. If the tightener is preassembled, proceed to step 11.
Note, check Crankshaft pulley alignment, pulley face should be 22mm from the end of the stub shaft (Image 1.1.5)

Refer to Image 1.1.6 for steps 4-6.
4. Install 5M-2057 seal-o-ring into 8N-9410 spacer and install onto shaft on 584-6616 Arm As.

5. Install one 8H-9789 bearing into pulley, and install 5S-2106 Seal into the same end of the pulley, using tooling A.

6. Install pulley onto shaft, and seat the seal onto 8N-9410 spacer. Install 584-6612 spacer onto shaft inside of the pulley and install the second 8H-9789 bearing into the pulley. Install 7W-8460 retaining washer with two 0L-2070 bolts.


7. Install 8N-9409 cover plate and 2N-8374 gasket with 0S-1617 bolts and 9M-1974 washers. Refer to Images 1.1.7 and 1.1.8 for final assembly of pulley onto arm.


8. Install 8B-1419 clevis pins into arm with 5P-8245 washers and 3B-4617 cotter pins. Refer to Image 1.1.9.

9. Install 6U-1989 relief fitting into the port on the end of the arm, and install 3B-6552 adapter into the port on the side of the arm, tighten hand tight plus two turns, ending with the fitting align pointing up the arm parallel to the center-line of the arm to slightly away from the pulley. Refer to Image 1.1.10.

10. Preassembling the grease line to the arm will aid in installation later. Install the 586-1409 grease hose into 6U-1989 adapter, with the hose guard at the adapter end, and tighten (Image 1.1.17). Install 242-8023 L-clip to hose, just past the end of the hose guard with 8C-7510 clip, 0S-1595 bolt 2x 5P-8245 washers, and 1F- 7958 nut. (Image 1.1.19)

11. Install the tightening arm onto the pivot shaft. (Image 1.1.11) Apply a small line of Loctite 263 or equivalent to the threads of the 0S-1594 bolt, and install into pivot shaft with 2M-2742 retainer plate, 8T-4896 flat washer, and 4D-1326 lock washer. (Image 1.1.12)

12. Remove two bolts and washers from lower fan drive mounting bracket (Images 1.1.13 and 1.1.14). Install 231-4471 bolt into 242-8023 L-clip (preassembled onto grease hose in step 10) on the right side of the engine and align the clip 15 degrees from horizontal (Image 1.1.15) and tighten the bolt.

13. Install 425-0545 bracket to side of front housing (below existing grease line for direct drive fan hub, if equipped) with 0S-1621 bolt and 5P-8245 washer, then install 3B-8686 grease zerk into the bracket. (Image 1.1.16)

14. Install the grease hose into the back of the bracket and tighten. (Image 1.1.18) If grease hose was preassembled in steps 10 and 12, proceed with Step 11 otherwise install 242-8023 L-clip to hose, just past the end of the hose guard with 8C-7510 clip, 0S-1595 bolt 2x 5P-8245 washers, and 1F-7958 nut. (Image 1.1.19)

15. Install 8C-7510 clip onto the grease hose, and install into the front housing with 231-4471 bolt and 292-3198 washer (Image 1.1.20), align clip 15 degree from horizontal (Image 1.1.21) and tighten bolt.

16. Fill the pulley with grease through the zerk with a hand grease gun until grease comes out the relief fitting.

17. Attach springs to tightener arm, (retighten 431-4097 bracket hardware if loosened in step 1).

18. End by install fan drive belts.
Image1.1.1
Image1.1.2
Image1.1.3
Image1.1.4
Image1.1.5
Image1.1.6
Image1.1.7
Image1.1.8
Image1.1.9
Image1.1.10
Image1.1.11
Image1.1.12
Image1.1.13
Image1.1.14
Image1.1.15
Image1.1.16
Image1.1.17
Image1.1.18
Image1.1.19
Image1.1.20
Image1.1.21
Image1.1.22
 
 

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