PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIFFERENTIAL PISTON HOUSING ON CERTAIN 740B ARTICULATED TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIFFERENTIAL PISTON HOUSING ON CERTAIN 740B ARTICULATED TRUCKS

Usage:

TEBE2536-01

Show/hide table

13Jan2015

(Revised 29Jan2016)

K260
K265
K363
K36C
K680
K690
Z850

Show/hide table

Containment - After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE DIFFERENTIAL PISTON HOUSING ON CERTAIN 740B ARTICULATED TRUCKS
3256 3258		PS61282

Show/hide table

NOTE:	Caterpillar’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 Caterpillar.
NOTE:	This Containment Program can only be administered after a failure occurs. 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.

Show/hide table

NOTE:

When reporting the repair, use "PS61282" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 13Jan2015 Service Letter. Changes have been made to the Termination Date.

Show/hide table

TERMINATION DATE

31Jan2017

PROBLEM

Show/hide table

The existing Piston Housing can experience premature wear generating debris in the Powertrain System on certain 740B Articulated Trucks.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
740B	L4E01762, 1773, 1795, 1800, 1830, 1968, 1976, 2123, 2131, 2150, 2156, 2162, 2182, 2189, 2192, 2195, 2197, 2199, 2205, 2207, 2211, 2213, 2215, 2217, 2219, 2221, 2223, 2323-2325, 2353, 2361, 2363, 2367, 2369, 2371, 2382, 2439, 2441-2442, 2445-2447, 2449, 2451-2452

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
6	2R0239	SEAL-O RING
12	1271960	SCREW-FLAT HEAD
3	3559368	SEAL-D-RING
3	3559369	SEAL-D-RING
6	3562456	SEAL-O-RING
3	4448152	WASHER-THRUST
3	4456671	PISTON HSG
3	4511415	WASHER-THRUST
1	BULK_OIL	Bulk Oil (693 Liter - 183 Gal) See OMM
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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

Show/hide table

Note: Please read all of the following information to determine what parts will need to be ordered.

Inspect machine SOS samples every 500 hours for an increase in iron "Fe" in the SOS sample for the front, center or rear differentials.

If one axle is showing high iron in the SOS samples compared to the fleet average this can point to excessive wear of the differential piston housing. If excessive wear is found on the inspected Piston Housing, replace the Piston Housing with part 445-6671.

NOTE: Please note the attached matrix for reworking axles prior to the effectivity stated in this After Failure Only Service Letter. Some axles will have the new thrust washer design and some axles will have the old design(no thrust washer). Only replace axles that are of the old design. After failure, all applicable axles should be reworked.

Reference Media Number UENR0207-01
Disassembly and Assembly, 735B, 740B and 740B Ejector Articulated Trucks Power Train
This media number details all other procedures required to R&I and D&A the units.

Refer to the attached Rework Procedure

Show/hide table

Image1

Image2

Image3

Image4

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 61-96 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

Show/hide table

NOTE: This is a 54.0-hour job If there has been a previous repair, part age/hours 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.
This job is 18.0 hours per each differential replaced. If determined that one differential has failed, replace the remaining two differentials on the vehicle based on the charts shown in the images in the Action Required. This is a maximum of a 54.0 hour job if all three differentials are replaced.

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Show/hide table

Reference Media Number UENR0207-?01
Disassembly and Assembly, 735B, 740B and 740B EJECTOR Articulated Trucks Power Train
This media number details all other procedures required to R&I and D&A the units.

1. Remove failed differential.
2. DO NOT fully disassemble the differentials.
3. Loosen bolts on Differential Lock Housing 152-4093 ( Refer to Item 33 in Image 1.1.1).
4. Remove housing and remove piston from housing.
5. Inspect hub 138-3638 (Refer to Item 19 in Image 1) for signs of material transfer or damage.
6. Only replace hub if unable to polish any damage out of surface (Image 1.1.2).

Image1.1.1

Image1.1.2

7. Inspect piston housing and measure to determine machining needed (Image 1.2.1 and 1.2.2). Reference Special Instruction REHS9418 for details on machining Piston Housing.

Image1.2.1

Image1.2.2

8. Clean newly machined mating surface of new housing (Image 1.3.1).
9. Install 451-1415 thrust washer. Clean back side of thrust washer (Image 1.3.2).
10. Apply Loctite 620 to the rear of the thrust washer as shown (Image 1.3.3).

Image1.3.1

Image1.3.2

Image1.3.3

11. Install thrust washer. Install 4 x 127?-1960 screws. DO NOT apply Loctite 620 to screw threads (Image 1.4.1).
12. Torque the 4 screws to a torque value 12 +/?- 3 Nm (Image 1.4.2).
13. Ensure that plate is level. Wipe excess Loctite from edges of the thrust washer internally and externally.
14. Reseal piston and reinstall (Image 1.4.3).