PRODUCT IMPROVEMENT PROGRAM FOR REWORKING REAR AXLE SPINDLES ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING REAR AXLE SPINDLES ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS

Usage:

REBE7936-04

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21Jun2012

(Revised 11Oct2012)

U-332

A-263

D-289

O-304

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING REAR AXLE SPINDLES ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS
4201		PI32047

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32047" 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 "PI32047" 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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NOTE:	This Revised Service Letter replaces the 21Jun2012 (Revised 30Aug2012) Service Letter. Changes have been made to to Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Dec2012	30Jun2013

PROBLEM

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The rear axle spindles need to be replaced on on certain 773F and 775F Off-Highway Trucks. The existing rear axle spindle can fail due to fatigue fracture in the bell housing.

AFFECTED PRODUCT

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Model	Identification Number
773F	EED00273-00274, 278, 280, 307-310, 324-325, 329, 332, 354-356, 360-361, 365, 368, 371, 374, 386-387, 389-392, 395, 400-402, 405, 420-422, 426-427, 438-442, 445, 452-453, 455, 458-459, 466-467, 470-474, 477, 481-482, 484, 494-495, 513, 517-518, 523, 532, 539, 541, 546-549, 552-554, 560-561, 565, 575-577, 579, 581-583, 592-594
775F	DLS00276, 278, 280, 286-288, 293, 303, 307, 312, 316-320, 325-328, 330, 333-334, 345, 347, 350, 352, 375, 382, 392-396, 400-401, 403, 407, 411, 419-421, 434-436, 446-450, 452-453, 456, 460-461, 463, 475, 492-494, 499, 501, 503, 505, 509, 517-518, 525, 529, 531, 533-534, 544, 562, 567, 581, 583, 585, 595, 598

PARTS NEEDED

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Qty	Part Number	Description
2	2A3398	GASKET
2	2M9780	SEAL-O-RING
2	3K0360	SEAL-O-RING
2	4D5738	SHIM
4	4J0527	SEAL-O-RING
2	4S5924	SEAL-O RING
2	5P4342	SEAL-O-RING
2	6F6672	SEAL-O RING
4	7J9108	SEAL-O-RING-ORFS
2	7Y0640	SEAL-O-RING
2	8L9241	SEAL-O-RING
20	8T0357	BOLT
2	9D7986	SEAL
2	9D7987	SEAL
2	9D7988	SEAL
4	9M5892	SEAL-O RING
2	1237268	SEAL-RING
4	1237271	SEAL-RING
2	1243520	SEAL-RING
2	2664594	RING-SEAL
2	3144128	SEAL GP-DUO CONE
2	3176441	SEAL GP-DUO CONE
4	3371943	SEAL-RECTANGULAR
2	3561487	SPINDLE-REAR
2	3564862	RETAINER-SEAL
2	3590854	SEAL-O-RING
2	3638821	SHIM GP-RAIL
2	3646486	HOUSING
NOTE: The 356-1487 Spindles are on allocation. Dealers are asked to enter the spindle orders for ALL affected machines IMMEDIATELY. Enter orders as PRIORITY 60?EMERGENCY or PRIORITY 90-STOCK and INCLUDE MACHINE MODEL and S/N. Please do not place orders for the other parts until notified that the spindles have been released for your specific machine(s).

ACTION REQUIRED

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Replace both rear spindles. Refer to Special Instruction REHS5086 "Procedure for Rear Wheel Spindle Removal and Installation" for the recommended spindle replacement procedure. Refer below to the additional steps that are required to install the improved duo-cone seal components at the same time that the spindles are replaced.

There is a slight chance that some affected machines may already have had steel spindles installed through alternate means. Refer to the attached photos to be able to quickly identify whether spindles are steel or ductile. If a machine is already equipped with steel spindles, this service letter DOES NOT need to be performed.

Damage the 255-8868 Spindles that are removed from the trucks sufficiently enough to prevent any possibility of reuse.

INSTALLATION OF IMPROVED DUO-CONE SEAL COMPONENTS

After the rear brake assembly is removed from the old spindle, disassemble the brake through Step 16 of RENR8286 Service and Parking Brake (Rear) ? Disassemble.

Install the 337-1943 Seals into the brake anchor.

Install the 9D-7986, 9D-7987, 123-7268, and 124-3520 Seals onto the 364-6486 Housing. Assemble the housing to the brake anchor.

Install the 9D-7988, 123-7271, and 266-4594 Seals onto the service brake piston. Install the piston into brake assembly.

Reinstall the dampers, separator plates and friction discs.

Install the 359-0854 Seal into the groove in the anchor and install the brake end plate.

Note: If the 318-2943 Brake Alignment Tool Group is not available, the splines on the wheel may be used to align the discs. To do this, position the wheel with the splined end up. Use an alternate pressure source attached to the "P" port on the brake anchor to retract the park brake piston. The pressure required to release the park brake is 450 psi. To avoid damage to the piston seals, do not exceed 730 psi. Position the brake discs so that they are centered and aligned as much as possible. Slowly lower the brake onto the wheel splines until all of the brake discs are engaged with the wheel splines. Release the pressure to lock the park brake before lifting the brake from the wheel and installing it onto the spindle.

After the new spindle is installed onto the axle housing, install the brake and 5P-4342 Seal onto the spindle. Reattach the brake lines using 4J-0527 and 2M-9780 Seals.

With the 1U-9200 Lever Puller Hoists and 138-7574 Link Brackets used in the removal of the brake, pull the brake inward against the spindle stops.

Install the retaining ring into the groove in the spindle. Using a feeler gage, measure the gap between the raised lugs on the brake housing and the retaining ring. Find the maximum thickness that can be inserted snugly between the housing and the retaining ring without having to use excessive force. Remove the retaining ring. Install shims from the 363-8821 Shim Pack equaling the measured thickness +0.00 / -
0.05 mm. Reinstall the retaining ring.

Before installing the wheels onto the new spindles, remove and discard the 256-7797 Retainers from the wheels and replace them with the new 356-4862 Retainers and 7Y-0640 O-Ring Seals.

Reinstall the wheel and final drive using the normal procedures in the Disassembly & Assembly manuals.

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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%

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NOTE: This is a 62.0-hour job

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PARTS DISPOSITION

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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 REWORKING REAR AXLE SPINDLES ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 773F and 775F Off-Highway Trucks

Dear Caterpillar Product Owner:

The rear axle spindles need to be replaced on the products listed below. The existing rear axle spindle can fail due to fatigue fracture in the bell housing. 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.

Due to limited World Wide Parts availability of 773F and 775F Spindles, Caterpillar will be distributing parts to dealers on a priority basis. Contact your Caterpillar dealer to determine your priority status.

Please refer the dealer to their Service Letter dated 21Jun2012 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 21Jun2012 Service Letter