PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRUCK FRAME ON CERTAIN 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRUCK FRAME ON CERTAIN 775F OFF-HIGHWAY TRUCKS

Usage:

TEBE0898-01

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04Feb2014

(Revised 18Mar2014)

X156

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRUCK FRAME ON CERTAIN 775F OFF-HIGHWAY TRUCKS
7051 0679		PS90360

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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 "PS90360" 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 04Feb2014 Service Letter. Changes have been made to the Parts Needed.

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TERMINATION DATE

28Feb2015

PROBLEM

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Cracks may be found in the rear stabilizer mount area of the frame on certain 775F Off-Highway Trucks. While making the repair, other areas will need to be inspected for cracks using the dye penetrant process and reworked if necessary. The affected areas are the right rear chassis tail casting, fuel tank mounting brackets, and accumulator mounting brackets, The pedestal mount on the left side of the chassis, under the cab.

AFFECTED PRODUCT

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Model	Identification Number
775F	DLS01210, 1222-1224, 1228-1230, 1232

PARTS NEEDED

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Qty	Part Number	Description
4	1P3705	SEAL-RECTANGULAR
2	1P3707	SEAL-RECTANGULAR
1	2M9780	SEAL-O-RING
6	3J1907	SEAL-O-RING
5	3K0360	SEAL-O-RING
2	4J0522	SEAL-O-RING
3	4J0524	SEAL-O-RING
12	4J0527	SEAL-O-RING
1	4M0189	SEAL-O RING
1	6J2680	SEAL-O RING
1	6V9746	SEAL-O-RING-ORFS
2	8L2746	SEAL-O-RING
2	1069586	SEAL-O-RING
2	1123540	SEAL-O-RING
2	1262702	SEAL-INTEGRAL
2	1367227	SEAL-O-RING
2	1986068	SEAL-INTEGRAL
2	3571752	GASKET
8	3912167	LOCKNUT-FLANGED
8	3935115	STUD-TAPERLOCK
1	BRAKE_TDTO_10W	Bulk Oil - See OMM for qty and specs.
1	HYD_HYDO_ADV_10W	Bulk Oil - See OMM for qty and specs.
1	XMNS_TDTO_30W	Bulk Oil - See OMM for qty and specs.
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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Carry out the existing Before and After Service Letters to rework the left and right side front frame Strut mounts. As a result further cracks can propogate up into the fore/aft beam causing additional damage and further additional rework to be performed. Additional labour support is required to Remove and Install major componenets and structures of the truck to allow access to the respective areas to be reworked.
In addition 3 areas will need to be inspcted for cracks and reworked as necessary.
Right Rear chassis frame tail casting around the axle stabiliser mount.
Cracks found around the Accumulator mounting brackets.
Cracks found in & around the main beam.

Carry out dye penetrant crack testing on the truck chassis frame in the
following area's.
- Right rear chassis/Frame stabilizer bar mounting.
- Accumulator mounting brackets.
- The main beam which has the rocker pad pedestals mounted.

If cracks are found in the area of the rear stabilizer mount on the rear chassis. Carry out crack repairs as per Special Instruction REHS5055 "Procedures for the Inspections, Repairs, and Component Replacements on the Frames and Support Assembly of Certain Off-Highway Trucks". See Image 1 below for the location.

If cracks are found in the area of the accumulator mounting brackets on the right side of the truck chassis frame, they need to be reworked in accordance to Special Instruction REHS5055 "Procedures for the Inspections, Repairs, and Component Replacements on the Frames and Support Assembly of Certain Off-Highway Trucks".

If cracks are found in the areas of the of the main beam of the truck chassis frame, they need to be reworked in accordance to Special Instruction REHS1841 "General Welding Procedures".

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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%
0-20000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job
This is a 1.00 hour job to crack test the specific areas of the chassis frame. - If cracks are found in this area of the accumulator mounts. Add an additional 4.00 hrs to carry out weld repairs around this area on the chassis. - If cracks are found in this area of the rear stabaliser mounting. Add an additional 3.50 hr to carry out weld repairs around this area of the chassis. - If cracks are found in this area of the main support beam. Add an additional 50 hr to remove the engine assemble from the frame In order to gain access carry out weld repairs the main beam of the chassis.