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

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

Usage:

TEBE4469-00

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28Sep2016

K030
K031

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE REAR AXLE HOUSING ON CERTAIN 785C AND 785D OFF-HIGHWAY TRUCKS
3260 0679		PS90637

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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 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 "PS90637" 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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TERMINATION DATE

30Sep2018

PROBLEM

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The existing rear axle housing can crack on certain 785C and 785D 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	APX01491-01492
785D	MSY00116-00117, 119, 133, 203-204, 206, 306-307, 309-310, 391, 425, 478-479, 513, 518-520, 539-542, 546, 551-554, 564-567, 579, 623, 646

PARTS NEEDED

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Qty	Part Number	Description
1	BOTTOM_CROSS_PLATE	Dealer Fabricated Plate
2	MITER_BLOCK_LEFT	Dealer Fabricated Plate
2	MITER_BLOCK_RIGHT	Dealer Fabricated Plate
2	STRUT_EAR_GUSSET	Dealer Fabricated Plate
1	TOP_CROSS_PLATE	Dealer Fabricated Plate
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 Image 1 below.

Refer to the Disassembly and Assembly Manual, Differential and Bevel Gear - Remove to gain access to the inside of the axle housing. The crack repairs to the axle housing and the addition of the stiffener plates (if required) can be done without removing the axle housing from the machine.

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.
Please refer to SEBF9393, "Rear Axle Stiffener Installation Procedure for 785, 789, 793 & 795 Off-Highway Truck", for instructions to install stiffener plates.

NOTE: These stiffener 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.
Before installing stiffeners, measure the amount of axle housing deflection as specified in the "Salvage of the Rear Axle Housing" section of REHS2346. Perform the specified salvage procedure if needed.

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Image1

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%
0-20000 hrs, 0-40 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
20001-40000 hrs, 41-80 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 72.0-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.
$1000 USD will be allowed for fabrication of the plates.

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