PRODUCT SUPPORT PROGRAM FOR REPLACING THE CENTER TUBE ASSEMBLY ON CERTAIN 793F, 793F AC, 793F CMD, AND 793F XQ OFF HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CENTER TUBE ASSEMBLY ON CERTAIN 793F, 793F AC, 793F CMD, AND 793F XQ OFF HIGHWAY TRUCKS

Usage:

TEBE4576-00

Show/hide table

17Jun2016

U-319

A-241

D-278

O-277

Show/hide table

Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CENTER TUBE ASSEMBLY ON CERTAIN 793F, 793F AC, 793F CMD, AND 793F XQ OFF HIGHWAY TRUCKS
7050 7051		PS45120

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 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 "PS45120" 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.

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

TERMINATION DATE

31Jan2020

PROBLEM

Show/hide table

Early hour frame cracking has been reported in the mid frame section on 793F, 793F XQ, and 793F CMD Off-Highway Trucks following the 12 gusset frame update. Crack initiation sites have been reported on the 4 bar link casting to main rail joint, pump drive box, cooler mounting blocks and the center tube to window plate joint.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
793F	SSP00117-00123, 125-127, 129-154, 157-162, 169-181, 183-186, 189, 191, 193-196, 198, 205-210, 212, 214, 216-217, 219, 233, 237-242, 245, 247-254, 257-260, 262-266, 269-270, 272-278, 280-287, 291, 296-297, 304-306, 308, 312-314, 318-319, 321-326, 328, 330, 332-339, 341-345, 348-350, 353-355, 357-360, 365, 367-368, 375, 384-389, 393-394, 396, 398-438, 441-442, 444, 446, 448-450, 452, 454, 458, 460-483, 485-493, 496-499, 501-504, 506, 508-512, 515-516, 519, 521-525, 528-547, 550-560, 563-593, 595-603, 605, 610-622, 624-626, 633-634, 636-638, 644-653, 655, 658-661, 663, 665, 667-684, 687-694, 696-700, 702-706, 709-711, 714-716, 718, 721-724, 728, 730-732, 734-735, 737-740, 742-743, 746-747, 749, 751, 755, 757-758, 761-764, 766-769, 773, 776-781, 784-785, 787-801, 803, 805, 807-810, 812-814, 816-819, 823-825, 829, 833, 837, 839-847, 850-859, 861-863, 865, 869-882, 887-888, 892-896, 898-900, 902, 904-907, 909-912, 914-915, 917-918, 921, 923-930, 932-936, 938-943
793F AC	EMD00075-00077
793F CMD	RBT00111-00123, 125-131, 133-140, 142-164
793F XQ	SND00100-00109, 111-131

Show/hide table

*******Group 2*******

793F

SSP00112, 114-116, 155-156, 164-168, 187-188, 190, 192, 211, 213, 215, 218, 220-232, 234-236, 267-268, 279, 288-290, 292-295, 298-303, 309-311, 315-317, 320, 327, 329, 331, 340, 346-347, 351, 361, 364, 369-374, 376-383, 390-392, 395, 439-440, 443, 445, 447, 451, 456-457, 459, 494-495, 505, 507, 513-514, 517-518, 520, 526-527, 548-549, 562, 604, 606-609, 623, 627-632, 635, 639-643, 654, 656-657, 662, 664, 666, 685-686, 695, 701, 717, 719, 726, 729, 733, 736, 744, 748, 750, 752-753, 759, 765, 770, 772, 774-775, 782-783, 786, 802, 804, 806, 811, 815, 820-822, 826-828, 830-832, 834-836, 838, 848-849, 860, 864, 866-868, 883, 889-891, 897, 901, 903, 908, 913, 916, 919-920, 922, 931, 937

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
4	4D6716	RIVET-POP
1	6C8258	BLOCK
2	7Y2522	PLATE
6	8X7415	PLATE
3	8Y3795	BOSS
1	8Y4489	BOSS
1	9C8710	BLOCK
7	9R2613	BOSS
1	9R3761	BOSS
2	2542995	PLATE
2	2944550	BOSS
2	3198260	PLATE AS.
1	3218602	PLATE
1	3404264	BLOCK
1	4317672	BRACKET AS
2	4317677	PLATE
1	4378748	BLOCK
2	4429937	PLATE
1	4843488	BRACKET AS
1	4944374	PLATE AS
2	4951548	PLATE
2	4951549	PLATE
1	4972266	SUPPORT AS
1	4988761	TREAD
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.
*****Group 2*****
4	4D6716	RIVET-POP
8	5P1076	WASHER-HARD
1	6C8258	BLOCK
2	7Y2522	PLATE
10	8T4183	BOLT-HEX HEAD
4	8T4194	BOLT-HEX HEAD
4	8T4223	WASHER-HARD
6	8T4244	NUT-HEX
23	8T4910	BOLT-HEX HEAD
6	8X7415	PLATE
3	8Y3795	BOSS
1	8Y4489	BOSS
1	9C8710	BLOCK
7	9R2613	BOSS
1	9R3761	BOSS
4	1729966	BOLT-HEX HEAD
51	1984778	WASHER-HARD
2	2542995	PLATE
2	2944550	BOSS
2	3198260	PLATE AS.
1	3218602	PLATE
1	3404264	BLOCK
1	4317672	BRACKET AS
2	4317677	PLATE
1	4378748	BLOCK
2	4429937	PLATE
1	4843488	BRACKET AS
1	4931624	PLATE
1	4931627	BRACKET AS
1	4931628	BRACKET AS
1	4931629	BRACKET AS
1	4931630	BRACKET AS
1	4931631	BRACKET AS
1	4944374	PLATE AS
2	4951548	PLATE
2	4951549	PLATE
1	4972266	SUPPORT AS
1	4988761	TREAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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

Group 1 and Group 2

1. Review Special Instruction M0069982, "Procedure to Replace the Center Tube Assembly on the 793F" completely.

2. Contact your Caterpillar Service Representative and LMT Product Support to review Special Instruction M0069982 with the management and welding team.

3. Contact your Caterpillar Service Representative and LMT Product Support to review and complete the Pre Frame Repair Checklist that is uploaded on the 793F product page on DEALER.CAT.COM under the ATTACHMENTS tab.

4. If required, contact your Caterpillar Service Representative to schedule Caterpillar onsite welding support.

5. If required, contact your Caterpillar Service Representative to obtain frame tooling and fixtures, refer to Special Instruction M0069982 for more details.

Group 2 Only - See the attached Rework Procedure.

Show/hide table

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%
*****Group 1*****
0-60000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 605.0-hour job for Group 1
An additional 22 labor hours may be claimed to remove and install the body. An additional 8 hours of labor may be claimed to repair each 4 Bar Link Casting to Main Rail Weld Joint (4 total) and Groove Welds in the Top Rails (2 total) that is found to have a crack or defect during visual inspection or non-destructive tests. An additional 6 labor hours or an allowance of $750 (if inspection is completed by a third party vendor) may be claimed to perform an overall visual frame inspection. Inspection results checklist and pictures must be attached to SIMSi when submitting the warranty claim. Refer to Special Instruction REHS7193 for inspection details and a checklist (Table 10) that may be used. An allowance of $3000 for welding consumables, welding blankets, ect. may be claimed. An allowance of $1,000 for contamination control material may be claimed. Due to the nature of this program additional Caterpillar parts that require replacement during the mechanical disassembly and assembly on the mid frame section may be claimed as required. These parts are limited to seals, gaskets, bolts, washers, nuts, locknuts, rings, clips, and clamps. An allowance of $215 for steel square tubing that is required to brace the frame may be claimed, refer to Special Instruction M0069982 for steel square tubing specifications. An allowance of $3500 for non-destructive tests (ultrasonic and magnetic particle testing) and visual inspections may be claimed. The NDT tests and visual inspections must be performed by qualified personnel in accordance with the qualifications specified in Special Instruction M0069982. It is required to attach all of the pictures listed in the ?Required Picture List? in Special Instruction M0069982 to SIMSi when submitting the warranty claim. Refer to the Special Instruction for additional details. It is required to attach a scanned copy of the completed and signed off Inspection and Test Plan listed in Special Instruction M0069982 to SIMSi when submitting the warranty claim. Only qualified and certified personnel are allowed to sign off on the Inspection and Test Plan, refer to Special Instruction M0069982 for qualified personnel requirements. The items listed in the inspection and test plan are the minimum inspections and tests that must be completed, signed off on, and attached to SIMSi when submitting the warranty claim. Similar Inspection and Test Plan documentation may be used with prior written approval from LMT Product Support. It is required to attach a completed NDT inspection report that coincides with the non-destructive tests listed in Special Instruction M0069982. It is recommended to use the blank NDT report that is uploaded to the 793F product page. Third party NDT company reports are allowed, but there are minimum informational requirements that each report must contain. Refer to ?793F Repair NDT Inspection Reports? Excel spreadsheet on the 793F/793F XQ product page on DEALER.CAT.COM under the ATTACHMENTS tab or contact your Caterpillar Service Representative for more information. The personnel who perform the welding and inspections (visual and non-destructive testing) on the frame as part of this program are required to attach certification documentation to SIMSi when submitting the warranty claim. The personnel and certification documentation should match the completed Inspection and Test Plan. Refer to Special Instruction M0069982 for qualified personnel requirements. Retain copies of all invoices from support, contracted services, and welding consumables for audit purposes.

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%
*****Group 2*****
0-60000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 608.0-hour job for Group 2
An additional 22 labor hours may be claimed to remove and install the body. An additional 8 hours of labor may be claimed to repair each 4 Bar Link Casting to Main Rail Weld Joint (4 total) and Groove Welds in the Top Rails (2 total) that is found to have a crack or defect during visual inspection or non-destructive tests. An additional 6 labor hours or an allowance of $750 (if inspection is completed by a third party vendor) may be claimed to perform an overall visual frame inspection. Inspection results checklist and pictures must be attached to SIMSi when submitting the warranty claim. Refer to Special Instruction REHS7193 for inspection details and a checklist (Table 10) that may be used. An allowance of $3000 for welding consumables, welding blankets, ect. may be claimed. An allowance of $1,000 for contamination control material may be claimed. Due to the nature of this program additional Caterpillar parts that require replacement during the mechanical disassembly and assembly on the mid frame section may be claimed as required. These parts are limited to seals, gaskets, bolts, washers, nuts, locknuts, rings, clips, and clamps. An allowance of $215 for steel square tubing that is required to brace the frame may be claimed, refer to Special Instruction M0069982 for steel square tubing specifications. An allowance of $3500 for non-destructive tests (ultrasonic and magnetic particle testing) and visual inspections may be claimed. The NDT tests and visual inspections must be performed by qualified personnel in accordance with the qualifications specified in Special Instruction M0069982. It is required to attach all of the pictures listed in the ?Required Picture List? in Special Instruction M0069982 to SIMSi when submitting the warranty claim. Refer to the Special Instruction for additional details. It is required to attach a scanned copy of the completed and signed off Inspection and Test Plan listed in Special Instruction M0069982 to SIMSi when submitting the warranty claim. Only qualified and certified personnel are allowed to sign off on the Inspection and Test Plan, refer to Special Instruction M0069982 for qualified personnel requirements. The items listed in the inspection and test plan are the minimum inspections and tests that must be completed, signed off on, and attached to SIMSi when submitting the warranty claim. Similar Inspection and Test Plan documentation may be used with prior written approval from LMT Product Support. It is required to attach a completed NDT inspection report that coincides with the non-destructive tests listed in Special Instruction M0069982. It is recommended to use the blank NDT report that is uploaded to the 793F product page. Third party NDT company reports are allowed, but there are minimum informational requirements that each report must contain. Refer to ?793F Repair NDT Inspection Reports? Excel spreadsheet on the 793F/793F XQ product page on DEALER.CAT.COM under the ATTACHMENTS tab or contact your Caterpillar Service Representative for more information. The personnel who perform the welding and inspections (visual and non-destructive testing) on the frame as part of this program are required to attach certification documentation to SIMSi when submitting the warranty claim. The personnel and certification documentation should match the completed Inspection and Test Plan. Refer to Special Instruction M0069982 for qualified personnel requirements. Retain copies of all invoices from support, contracted services, and welding consumables for audit purposes.

PARTS DISPOSITION

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

Rework Procedure

Group 2 Only

For machines configured with the Extra Retarding Cooling Arrangement, refer to Special Instruction M0073048 "Procedure to Rework the Brake Oil Cooler Mounting on Certain 793F Off-Highway Trucks" for the updated auxiliary brake oil cooler mounting instructions.

Note: The Brake Oil Cooler Mounting will be updated while the Oil Cooler Core Group is removed from the machine.