PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT ROCKER TOWERS ON CERTAIN 795F AC OFF HIGHWAY TRUCK COAL BODIES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT ROCKER TOWERS ON CERTAIN 795F AC OFF HIGHWAY TRUCK COAL BODIES

Usage:

TEBE0874-00

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14Feb2014

U-84

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT ROCKER TOWERS ON CERTAIN 795F AC OFF HIGHWAY TRUCK COAL BODIES
7258 0679		PS44184

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44184" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS 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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TERMINATION DATE

29Feb2016

PROBLEM

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The existing front rocker towers can develop cracks at the weld between the landing pad plates and the front rocker tower supports on certain 795F AC OfF-Highway Trucks equipped with 380-8200 or 312-5200 Coal Bodies. This failure mode is more prevalent at sites with soft underfoot conditions. If the existing front rocker towers develop cracks it can/will result in reduced product life.

AFFECTED PRODUCT

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Model	Identification Number
793F TRUCK BODY	EKC00351-00355, 436-440

PARTS NEEDED

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Qty	Part Number	Description
2	PLATE_A	DEALER FABRICATED PART
2	PLATE_B	DEALER FABRICATED PART
6	PLATE_C	DEALER FABRICATED PART
2	PLATE_D	DEALER FABRICATED PART
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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See the attached Rework Procedure.

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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%
0-30000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-hour job
A Maximum of $500.00 U.S. will be allowed for labor and materials to fabricate the parts shown in the illustrations. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the machine folder for audit purposes.

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PARTS DISPOSITION

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

Rework Procedure

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Refer to the Service Manual if/as necessary.

Listed are the parts and quantities required for the rocker tower rework. The dealer will be responsible for the fabrication of these parts. Following the parts list is a generic rework procedure.

Material specification for fabricated parts:
Plates A-B-C-D: Steel-Structural (550 MPa Min Yield) ASTM A656/A656M Grade 80

Image1.1.1

Image1.1.2

Image1.1.3

Image1.1.4

Reference REHS1841 General Welding Procedures

The following welding processes are acceptable for this procedure:

?Gas metal arc welding (GMAW) Use 35 +/- 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The AWS Class ER70S-3 is a welding process that can be used with the following welders: Lincoln L-50 and Hobart HB-25.

?Flux cored arc welding (FCAW) Use 35 +/- 5 cubic feet per hour of shielding gas (75% argon and 25% carbon dioxide). The FCAW process is called the AWS Class E71T-1 process.

?Shielded metal arc welding (SMAW) Use E7018 electrodes in this DCEP process.

?Air arc gouging (DCEP) Use 5/16 inch diameter rods for carbon arc.

Remove plates indicated in Image 1.3.1 on both rocker towers.