Usage:
January 6, 2006
(Revised July 2006)
U-8
A-8
D-8
O-9
before
or after failure |
PRODUCT SUPPORT PROGRAM FOR REPAIRING OR REPLACING THE REAR CAB SUPPORT ON CERTAIN 768C, 772B, 776, AND 776B OFF-HIGHWAY TRACTORS; AND ON CERTAIN 769C, 769D, 771C, 771D, 773B, 773D, 773E, 775B, 775D, 775E, 777, AND 777B OFF-HIGHWAY TRUCKS |
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7264 7266 7301 |
PS41889
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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.
NOTE: This Revised Service Letter replaces the January 6, 2006 Service Letter. Changes have been made to the Affected Product, Parts Needed, Action Required, and Service Claim Allowances.
Termination Date
January 31, 2009PROBLEM
The rear cab support needs to be repaired or replaced on certain 768C, 772B, 776, and 776B Off-Highway Tractors; and on certain 769C, 769D, 771C, 771D, 773B, 773D, 773E, 775B, 775D, 775E, 777, and 777B Off-Highway Trucks. Corrosion may occur inside the left end of the main beam of the frame and inside the rear cab support. With few exceptions, corrosion will not be apparent from the exterior of machine.AFFECTED PRODUCT
Model | Identification Number |
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768C | 02X00001-371 |
769C | 01X00001-502, 504-1210, 1212-1223, 1225-1875, 1877-1951, 1953-2037, 2039-2146, 2148-2314, 2316-2948, 2950-2956, 2958-3203, 3205-3211, 3213-3221, 3223-3489, 3491-5473, 75387-75396, 75398, 75399, 78001, 78002 |
Model | Identification Number |
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768C | 02X00372-403 |
769C | 01X05474-7151 |
769D | 5TR00001-1054 |
771C | 3BJ00001-281 |
771D | 6JR00001-309 |
Model | Identification Number |
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769D | BBB00001-522 |
769D | 5SS00001-652 |
771D | BCA00001-370 |
771D | 6YS00001-441 |
Model | Identification Number |
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772B | 64W00001-137, 143-152, 154-180, 75132, 75133, 75135, 75136, 75138, 75139 |
773B | 63W00001-158, 160-196, 198-213, 215-244, 246-552, 554-625, 627-710, 712-765, 767-778, 780-804, 806-824, 826-903, 905-971, 973-1455, 1457-1488, 1490-1666, 1668-1674, 1676-1785, 1787-1795, 1798-1829, 1831-1906, 1908-1951, 1953-2258, 2260-2340, 2342-2495, 2497-3016, 3018-3295, 75118-75129, 75132-75133, 75200-75208, 75210, 75213, 76002 |
Model | Identification Number |
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772B | 64W00181-303 |
773B | 63W03296-3376, 3378-3464, 3467-3608, 3610-3794, 3796-3943, 3945-4081, 4083-4614, 4616-4690, 75130, 75131, 75134, 75135, 75209, 75211, 75212, 76001 |
775B | 7XJ00001-100, 102-208, 210-286, 288-310, 312-345, 76001-76004 |
Model | Identification Number |
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773D | 7ER00001-971 |
773D | 7CS00001-7445 |
773E | BDA00001-844 |
775D | 6KR00001-380 |
775D | 8AS00001-534, 536-631, 76001 |
775E | BEC00001-549 |
Model | Identification Number |
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776 | 14H00001-35 |
777 | 84A00001-129, 130-163, 75107 |
Model | Identification Number |
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776 | 14H00036-55, 58-135 |
777 | 84A00164-214, 216-225, 227-231, 233-249, 251-272, 275-295, 297-338, 340-348, 350-373, 375-413, 415-463, 465-478, 480-509, 511-559 75042-75044, 75050, 75052, 75056-75058, 75061, 75062, 75101-75106 |
Model | Identification Number |
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776 | 14H00136-205 |
777 | 84A00560-575, 577-702, 704-817, 819, 821, 823-890, 892-944, 946-953, 955-993, 995-1173, 1175-1283, 75038-75041, 75048, 75049, 75051, 75059, 75060, 75120 |
Model | Identification Number |
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776 | 14H00206-217 |
777 | 84A01284-1358, 1360-1546, 1548-1554, 1556-1772, 1776-1789, 75045-75047, 75053-75055 |
Model | Identification Number |
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776B | 6JC00001-58, 61-108, 75200, 75201 |
777B | 4YC00001-113, 115-119, 121-129, 131-152, 154-300, 302-305, 307-557, 559-956, 959-1143, 1145-1220, 1222-1468, 1470-1471, 1473-1481, 1483-1492, 1494-1514, 1517-1545, 1547-1866, 75059-75072, 76001-76004 |
PARTS NEEDED
Material requirements vary depending on; 1) truck/tractor model and 2) inspection results. To repair a particular machine, some portion or all of the material listed below may be required:
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***** Replace the tube assembly, apply silicone ***** |
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1 | 2528658 | TUBE AS |
1 | 2528660 | ELBOW |
1 | 2528661 | SEAL-RING |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** reinforce the structure, and apply silicone ***** |
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8 | 1D4631 | BOLT |
8 | 9S1351 | BOLT |
1 | 2528658 | TUBE AS |
1 | 2528660 | ELBOW |
1 | 2528661 | SEAL-RING |
1 | 2643681 | PLATE |
1 | 2643683 | PLATE |
1 | 2643684 | PLATE |
1 | 2643685 | PLATE |
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***** Replace the tube assembly, apply silicone ***** |
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1 | 2528658 | TUBE AS |
1 | 2528660 | ELBOW |
1 | 2528661 | SEAL-RING |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the structure, apply silicone ***** |
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8 | 5B5473 | BOLT |
8 | 6H1628 | BOLT |
12 | 8W7825 | SLEEVE |
4 | 8W9014 | SLEEVE |
32 | 9W9876 | MOUNT-CAB |
1 | 2528658 | TUBE AS |
1 | 2528660 | ELBOW |
1 | 2528661 | SEAL-RING |
1 |
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PLATE |
1 | 2643680 | PLATE |
1 | 2643681 | PLATE |
1 | 2643682 | PLATE |
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***** Replace the tube assembly, apply silicone ***** |
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1 | 2528658 | TUBE AS |
1 | 2528660 | ELBOW |
1 | 2528661 | SEAL-RING |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the structure, apply silicone ***** |
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8 | 5B5473 | BOLT |
8 | 6H1628 | BOLT |
32 | 1630042 | MOUNT-CAB |
12 | 1633127 | SLEEVE |
4 | 1837802 | SLEEVE |
1 | 2528658 | TUBE AS |
1 | 2528660 | ELBOW |
1 | 2528661 | SEAL-RING |
1 | 2643678 | PLATE |
1 | 2643679 | PLATE |
1 | 2643680 | PLATE |
1 | 2643681 | PLATE |
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***** Replace the tube assembly, apply silicone ***** |
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1 | 2528664 | TUBE AS |
1 | 2528665 | ELBOW |
1 | 2528666 | SEAL-RING |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the structure, apply silicone ***** |
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8 | 1D4631 | BOLT |
4 | 1D4643 | BOLT |
4 | 9S1351 | BOLT |
1 | 2528664 | TUBE AS |
1 | 2528665 | ELBOW |
1 | 2528666 | SEAL-RING |
1 | 2643689 | PLATE |
1 | 2643691 | PLATE |
1 | 2643692 | PLATE |
1 | 2643693 | PLATE |
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***** Replace the tube assembly, apply silicone ***** |
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1 | 2528664 | TUBE AS |
1 | 2528665 | ELBOW |
1 | 2528666 | SEAL-RING |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** reinforce the structure and, apply silicone ***** |
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8 | 5B5473 | BOLT |
4 | 6H1628 | BOLT |
4 | 6V2624 | BOLT |
12 | 8W7825 | SLEEVE |
4 | 8W7881 | SLEEVE |
32 | 9W9876 | MOUNT-CAB |
1 | 2528664 | TUBE AS |
1 | 2528665 | ELBOW |
1 | 2528666 | SEAL-RING |
1 | 2643689 |
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1 | 2643691 |
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1 | 2643692 |
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1 | 2643693 |
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***** Replace the tube assembly, apply silicone ***** |
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1 | 2528664 | TUBE AS |
1 | 2528665 | ELBOW |
1 | 2528666 | SEAL-RING |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the structure, apply silicone ***** |
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8 | 5B5473 | BOLT |
4 | 6H1628 | BOLT |
4 | 6V2624 | BOLT |
32 | 1630042 | MOUNT-CAB |
12 | 1633127 | SLEEVE |
4 | 1837801 | SLEEVE |
1 | 2528664 | TUBE AS |
1 | 2528665 | ELBOW |
1 | 2528666 | SEAL-RING |
1 | 2643692 | PLATE |
1 | 2643696 |
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1 | 2643697 | PLATE |
1 | 2646168 | PLATE |
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***** Replace the tube assembly, clean, and apply coating ***** |
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4 | 1D4631 | BOLT |
10 | 2H3741 | BOLT |
1 | 2396947 | PLATE |
1 | 2692119 | SEAL RING |
1 | 2692120 | TUBE AS. |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the main beam ***** |
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4 | 1D4631 | BOLT |
10 | 2H3741 | BOLT |
1 | 2367499 | PLATE |
1 | 2396947 | PLATE |
1 | 2692119 | SEAL RING |
1 | 2692120 | TUBE AS. |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the main beam ***** |
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10 | 3B4510 | WASHER |
4 | 1D4631 | BOLT |
1 | 9D3272 | SUPPORT |
10 | 8S9092 | BOLT |
1 | 2367499 | PLATE |
1 | 2396947 | PLATE |
1 | 2692119 | SEAL RING |
1 | 2692120 | TUBE AS. |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the main beam ***** |
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10 | 3B4510 | WASHER |
4 | 1D4631 | BOLT |
1 | 2G5815 | SUPPORT |
10 | 1K4744 | BOLT |
1 | 2396947 | PLATE |
1 | 2367499 | PLATE |
1 | 2692119 | SEAL RING |
1 | 2692120 | TUBE AS. |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the main beam ***** |
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4 | 1D4631 | BOLT |
10 | 2H3741 | BOLT |
10 | 0S1575 | BOLT |
1 | 5T8114 | SUPPORT |
1 | 2396947 | PLATE |
1 | 2367499 | PLATE |
1 | 2692119 | SEAL RING |
1 | 2692120 | TUBE AS. |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** reinforce the main beam, and replace the ***** ***** rear cab support outrigger ***** |
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6 | 1D4631 | BOLT |
10 | 2H3741 | BOLT |
1 | 2367499 | PLATE |
1 | 2396947 | PLATE |
1 | 2421303 | SUPPORT AS. |
1 | 2692119 | SEAL RING |
1 | 2692120 | TUBE AS. |
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***** Replace the tube assembly, clean, and apply coating ***** |
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6 | 1D4643 | BOLT |
10 | 5P8250 | WASHER-HARD |
12 | 5T8128 | MOUNT |
6 | 5T8138 | SLEEVE |
1 | 2312812 | SEAL - RING |
1 | 2396947 | PLATE |
1 | 2471963 | PIPE AS. |
1 | 2503871 | TUBE ASSEMBLY |
1 | 2509182 | COVER |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** and reinforce the main beam ***** |
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6 | 1D4643 | BOLT |
10 | 5P8250 | WASHER-HARD |
12 | 5T8128 | MOUNT |
6 | 5T8138 | SLEEVE |
1 | 2312812 | SEAL - RING |
1 | 2367499 | PLATE |
1 | 2396947 | PLATE |
1 | 2471963 | PIPE AS. |
1 | 2503871 | TUBE ASSEMBLY |
1 | 2509182 | COVER |
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***** Replace the tube assembly, clean, and apply coating, ***** ***** reinforce the main beam, and replace the ***** ***** rear cab support outrigger ***** |
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6 | 1D4643 | BOLT |
10 | 5P8250 | WASHER-HARD |
12 | 5T8128 | MOUNT |
6 | 5T8138 | SLEEVE |
1 | 2312812 | SEAL - RING |
1 | 2367499 | PLATE |
1 | 2396947 | PLATE |
1 | 2421302 | SUPPORT AS. |
1 | 2471963 | PIPE AS. |
1 | 2503871 | TUBE ASSEMBLY |
1 | 2509182 | COVER |
ACTION REQUIRED
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Below Min |
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Replace Exhaust And Apply Silicone (4C9614) Around Baffle |
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Replace Exhaust, Clean (174-6858 or 1U5490) and Coat (Loctite Extend or 7500) Interior of Beam. Weld Reinforcement Plates, and Apply Silicone (4C9614) Around Baffle |
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Option Number |
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Below Min |
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Option 1 |
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Replace Exhaust, Clean (174-6858 or 1U5490) and Coat (Loctite Extend or 7500) Interior of Beam and Outrigger. Weld Internal Baffle |
Option 2 |
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Replace Exhaust, Clean (174-6858 or 1U5490) and Coat (Loctite Extend or 7500) Interior of Beam and Outrigger. Weld Main Beam Reinforcement Plate (if needed), Weld Plate Into End Of Main Beam. |
Option 3 |
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Replace Exhaust, Replace Outrigger, Clean (174-6858 or 1U5490) and Coat (Loctite Extend or 7500) Interior of Beam, Weld Main Beam Reinforcement Plate (if needed), Weld Plate Into End Of Main Beam. |
Refer to inspection results from PI30835. This Program must be used after PI30835. Dealers will attempt to prioritize machine repairs within its service territory based on the inspection results obtained in PI30835. Machines with the most severe corrosion will be repaired first. Using the applicable special instructions, repair the machine main beam and rear cab support. See below.
Following the structural repair of the machine,
replace a portion of the exhaust system. All repairs must be performed
as specified in the special instructions. State the repair option used
for the repair. Enter the repair option used into SIMS in the Claim Story
section. If the first repair option that specifies replace the tube assembly,
clean the interior (777 Only), and apply coating (777 Only) is used, description
code "U" should be used as the SIMS description code. If the second repair
option that specifies replace the tube assembly, clean the interior, apply
coating, and reinforce the main beam is used, description code "T" should
be used as the SIMS description code. If the third repair option (777 Only)
that specifies replace the tube assembly, clean the interior, apply coating,
reinforce the main beam, and replace the outrigger is used, description
code "B" should be used as the SIMS description code.
Repair Procedure:
1. Replace a portion of the exhaust system in the main beam as specified below:
a. For 768C, 769C, 769D, 771C, and 771D remove the existing tube assembly and install 1 - 2528658 Tube As, 1 - 2528660 Elbow, and 1 - 2528661 Seal Ring.
b. For 772B, 773B, 773D, 773E, 775B, 775D, and 775E, remove the existing tube assembly and install 1 - 2528664 Tube As, 1 - 2528665 Elbow, and 1 - 2528666 Seal Ring.
c. For 776, and 777 Off-Highway Trucks remove the existing 2G-3238 Tube Assembly and install 269-2120 Tube Assembly and 269-2119 Seal-Ring.
d. For 776, 776B, 777, and 777B Off-Highway
Trucks remove the existing 5T-6767 Tube Assembly and install 247-1963 Tube
Assembly, 231-2812 Seal-Ring, 250-9182 Cover, and 250-3871 Tube Assembly.
2. Repair the main beam of the frame and rear cab support of the machine as indicated in the special instruction specific to the truck/tractor model. In certain situations, a temporary repair will be indicated. Read and understand the appropriate special instruction before proceeding:
a. For 768C, 769C, 769D, 771C, and 771D refer to media number: REHS2536.
b. For 772B, 773B, 773D, 773E, 775B, 775D, and 775E refer to media number: REHS2537.
c. For 776, 776B 777, and 777B refer to media
number: REHS1773.
If 174-6858 Cleaner is not readily available, use 1U-5490 Degreaser. If neither are available, obtain a heavy duty detergent/degreaser or a heavy duty alkaline cleaner from a local source. One gallon of degreaser will repair a mining truck.
...Loctite Coating
The required Loctite Coating is not available
through the parts system. Obtain Extend Rust Preventative from a local
Loctite source. In Europe, this product is called Loctite 7500. No other
substitutes are acceptable.
To find ordering information for Loctite Extend, go back to Loctite's home page at www.loctite.com and select the appropriate country. From the next web page, select "Data Sheets/Quality Information." From the next web page, select "Technical Data Sheets." From the next web page, where a product name or number can be entered, enter "Extend" or "Loctite 7500." A two-page technical data sheet will be displayed which will include ordering information. Order the quantity of product required. One liter of Extend will repair two mining trucks.
SERVICE CLAIM ALLOWANCES
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0-Up Months |
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***** Replace Tube, Clean, Apply Coating, and Reinforce Structure ***** |
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0-Up Months |
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***** Replace Tube, Clean, and Apply Coating ***** |
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0-Up Months |
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***** Replace Tube, Clean, Apply Coating, and Reinforce Structure ***** |
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***** Replace Tube, Clean, Apply Coating, Reinforce Main Beam, ***** ***** And Replace Cab Support Outrigger ***** |
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0-Up Months |
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