PRODUCT SUPPORT PROGRAM FOR REPAIRING THE REAR AXLE HOUSING ON CERTAIN 785C OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE REAR AXLE HOUSING ON CERTAIN 785C OFF-HIGHWAY TRUCKS

Usage:

TEBE0482-01

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21Mar2014

(Revised 14May2014)

K314
K430

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE REAR AXLE HOUSING ON CERTAIN 785C OFF-HIGHWAY TRUCKS
3260		PS90375

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NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90375" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as 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.

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NOTE:	This Revised Service Letter replaces the 21Mar2014 Service Letter. Changes have been made to the Termination Date and Service Claim Allowances.

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TERMINATION DATE

31Mar2016

PROBLEM

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The existing Rear Axle Housings may crack on certain 785C Off-Highway Trucks. If the existing housing cracks it can result in leaking oil and unplanned downtime.

AFFECTED PRODUCT

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Model	Identification Number
785C	APX01640, 1643-1644, 1650-1651, 1655-1660, 1666-1668, 2025-2027, 2037, 2039, 2051, 2079-2082, 2084, 2228

PARTS NEEDED

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Qty	Part Number	Description
2	PLATE_1	DEALER FABRICATED PART
2	PLATE_2	DEALER FABRICATED PART
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

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NOTE: This program only covers housings with either the "CHINA" or "SS" foundry logos, as shown in Image1 below.

Refer to the Disassembly and Assembly Manual SENR1490, section "Differential and Bevel Gear - Remove" to gain access to the inside of the axle housing.

Please refer to REHS2346, Reuse And Salvage Guidelines, "Weld Repair Procedure for the Rear Axle A-Frame and Rear Axle Housing on 785, 789, and 793 Off-Highway Trucks", specifically the section titled "Salvage of the Rear Axle Housing", for instructions to weld repair cracks and install stiffening plates.

NOTE: These stiffening plates do not add to the load carrying capability, but only work to ensure that the rear axle housing will meet durability expectations when Caterpillar load recommendations and Operating and Maintenance Manual recommendations for loading are followed.

Over time, the rear axle housing may deflect due to excessive load. Refer to Image 2 below in order to determine the salvage options that are available for the rear axle housing. Measure the distance between the left and right spindle mounting faces at both the bottom (A) and the top (B) of the axle housing. Subtract measurement (B) from measurement (A) to determine the amount of deflection.

If the deflection is found to be less than 7mm, the stiffener plates can be added to the axle housing with no further modifications required.

If the deflection is found to exceed 7mm, an evaluation of the failure must be completed. Please provide your local Caterpillar Service Representative with the machine S/N, SMU, and payload history. The Service Representative will then contact Caterpillar to determine the recommended salvage procedures.

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Image1

Image2

SERVICE CLAIM ALLOWANCES

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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%
0-35000 hrs, 0-80 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 290.0-hour job
NOTE: The 290.0 hours includes all labour to remove axle housing and perform the welding of the plates. $2200 USD will be allowed for the fabrication of the plates.

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