PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MACHINE JACKING PLATES ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MACHINE JACKING PLATES ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS

Usage:

TEBE2841-00

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29Apr2015

U-204

A-140

D-159

O-161

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MACHINE JACKING PLATES ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS
3260 7750		PI32480

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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 Program must be administered as soon as possible. When reporting the repair, use "PI32480" 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 "PI32480" 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:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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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COMPLETION DATE	TERMINATION DATE
31Oct2015	30Apr2016

PROBLEM

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The rear axle housing needs to be modified to include jacking pads on certain 795F AC Off-Highway Trucks. The existing rear axle housing can can be damaged by jacking the machine on the bottom surface of the housing.

AFFECTED PRODUCT

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Model	Identification Number
795F AC	ERM00151-00296
795F XQ	SNT00100-00101

PARTS NEEDED

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Qty	Part Number	Description
4	PLATE	DEALER FABRICATED PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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****Parts Stock ****

Rework all 286-8074 Housings in dealer parts stock according the rework instructions provided.

****Affected Product****

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts reworked in dealer parts stock.

****Affected Product****

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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 12.0-hour job
Up to $600 (USD) will be allowed for materials and fabrication of the jacking plates required to complete this rework.

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MACHINE JACKING PLATES ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 795F AC OFF-HIGHWAY TRUCKS

Dear Cat Product Owner:

The rear axle housing needs to be reworked on the products listed below. The existing rear axle housing can be damaged by jacking the machine on the bottom surface. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 29Apr2015 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 29Apr2015 Service Letter

Rework Procedure

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In order to prevent axle housing damage during maintenance and service procedures (4) lifting points are to be added to existing axle housing
Image 1.1.1 and 1.1.2 show the general location of each (4) jack lifting pads (red)
Jack contact pads do not require any truck disassembly for installation
Jack contact pads are dealer fabricated parts and are attached to the axle housing by welding.

Image1.1.1

Image1.1.2

JACK PAD FABRICATION DETAILS:

Jack pad material:
Structural Steel, 290MPa yield / 435MPa ultimate tensile strength ?150MM X 50MM thick (?6inch X 2inch)
60? bevel all weld connection edges
Welding ? Per REHS2346
Certified and qualified welding technician

Filler materials
SMAW E7018 low hydrogen electrode
FCAW E71T-1 flux cored welding electrode

Inspection: Trained level 3 technician
Visual ? all surfaces of casting
Magnetic particle ? installation surfaces and all stiffener plate welds

Image1.2.1

INSTALLATION OF THE JACK PADS ON THE REAR OF THE HOUSING (INNER STRUT EAR POSITION)

Install (2) temporary tie bars, remove after welding (see Image 1.3.1). This will provide support against material deflection during the installion of the jack pads.

Image1.3.1

Surface preparation, notch inner ears only (see Image 1.4.1)
Air arc / torch permitted, finish with grinder and 180 grit pad
60? weld bevel after notch is formed, all edges

Image1.4.1

Center the jack pad in the notch (see Image 1.5.1)
Weld jack pad to axle housing

Note: Use a level to ensure that the lifting pad is installed parallel with the ground

Image1.5.1

INSTALLATION OF THE FORWARD JACK PADS (LOWER LINK EAR POSITION)

Install (2) temporary tie bars, remove after welding (see Image 1.6.1)

Surface preparation
Grind casting flat at interface, finish with 180 grit pad
60? weld bevel either edge of suspension ear

Center the jack pad on ear at specified dimension (see Image 1.6.1)

Image1.6.1

Weld jack pad to axle housing (see Image 1.7.1)

Note: Use a level to ensure that the lifting pad is installed parallel with the ground

Image1.7.1

Additional fabrication options exist and can be implemented based on the jacking equipment that will be used on the specific machine. One example (see Image 1.8.1) is the addition of material around the OD of the jack pad. Additionally, a recess could be machined into the bottom of the jack pads. The advantage of this would be to help center the jack during service and provide additional support against any side loading that may occur during service.