PRODUCT SUPPORT PROGRAM FOR REPLACING CRACKED FRONT AXLE ASSEMBLIES AT PCR ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING CRACKED FRONT AXLE ASSEMBLIES AT PCR ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS

Usage:

SEBE9203-01

June 1, 2005
(Revised October 2006)
U-177
A-134
D-145

Show/hide table

*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING CRACKED FRONT AXLE ASSEMBLIES AT PCR ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS
4001 4006 4251 7200		PS50977

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 "PS50977" 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: 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.

NOTE: This Revised Service Letter replaces the June 1, 2005 Service Letter. Changes have been made to the Parts Needed.

TERMINATION DATE

June 30, 2007

PROBLEM

The front axle assemblies on certain 797 and 797B Off-Highway Trucks may not meet the reusability guidelines at PCR because cracks were found during the magnetic particle and/or dye penetrate inspection process. Weld repair on the cracks is not an option.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
797	5YW00001-Up
797B	JSM00001-Up

PARTS NEEDED

Show/hide table

Quantity	Part Number	Description
1*	10R4127	AXLE AS
* One per side or two per truck.

ACTION REQUIRED

During any planned component rebuild check the axle assembly for cracks using the magnetic particle and dye penetrate inspection process. If cracks are found and determined to be more than 16 mm in length replace the existing axle assembly with a 10R4127 Axle Assembly. Weld repair by the dealer is not an option at this time. NOTE: Record the location of all cracks. See the Illustration under Service Claim Allowances.

SERVICE CLAIM ALLOWANCES

Note: This program will cover all cracked axle assemblies. Axle assembly life is affected by loading practices. The service allowance will be based on adherence to the 10/10/20 policy and the locations of the cracks. Use Table A for cracked axle assemblies that have been removed from trucks that have not violated the 10/10/20 policy.

Use Table A for cracked axle assemblies that have been removed from trucks that have violated the 10/10/20 policy and have cracks limited to the LOAD ZONES only.

Use Table B for cracked axle assemblies that have been removed from trucks that have violated the 10/10/20 policy and have cracks in the LOW STRESS ZONES only.

See graphic below for further guidelines on load and low stress zones for axle assemblies.

Show/hide table

Table A
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
0-20,000 Hours 0-Up Months	100%	n/a	0	0	0	0
20,001-40,000 0-Up Months	56 %	n/a	0	0	33 %	0
40,001-60,000 Hours 0-Up Months	11 %	n/a	0	0	67 %	0
NOTE: This program can only be implemented at PCR or any planned rebuild. No labor is allowed.
NOTE: If there has been a previous repair, part age will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

Show/hide table

Table B
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
0-20,000 Hours 0-Up Months	56 %	n/a	0	0	33 %	0
20,001-40,000 0-Up Months	11 %	n/a	0	0	67 %	0
40,001-60,000 Hours 0-Up Months	0 %	n/a	0	0	100 %	0
NOTE: This program can only be implemented at PCR or any planned rebuild. No labor is allowed.
NOTE: If there has been a previous repair, part age will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.