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


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PRODUCT SUPPORT PROGRAM FOR REPLACING THE CENTER TUBE ASSEMBLY ON CERTAIN 793F AND 793F CMD OFF-HIGHWAY TRUCKS [UEBE0344]
FRAME AND BODY
FRAME GP
PRODUCT SUPPORT PROGRAM FOR REPLACING THE CENTER TUBE ASSEMBLY ON CERTAIN 793F AND 793F CMD OFF-HIGHWAY TRUCKS
UEBE0344-03

20Feb2020
(Revised 19Sep2020)


U-83
A-65
D-78
O-76

 

Before/After

  
  

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

7051 7050
PS46578
NOTE:

AVSpare’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 AVSpare.

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 "PS46578" 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.

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 AVSpare product analyst.

 
NOTE:

This Revised Service Letter replaces the 20Feb2020 (Revised 20Jul2020) Service Letter. Changes have been made to the Affected Product.


TERMINATION DATE

28Feb2021

PROBLEM

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

Model Identification Number
*******Group  1*******
793F  SSP00141-00142, 144-146, 148-149, 153, 159, 180, 239, 262-263, 308, 318, 348, 350, 353, 384, 386, 388, 408-409, 435, 502, 537, 540, 544, 550, 553, 573, 575, 578, 581, 637, 645-647, 650, 672, 732, 734, 743, 757, 762, 807, 816-819, 823-824, 839, 843-844, 858, 861, 898, 909, 923, 932, 938
793F CMD  RBT00114, 119-120, 128, 143, 152
*******Group  2*******
793F  SSP00114, 236, 294-295, 298, 309-310, 327, 373, 378-379, 456, 518, 520, 549, 686, 726, 733, 736, 774, 822, 826-827, 831-832, 835, 838, 883, 889-891, 897, 901, 903, 908, 913, 916, 919-920, 922, 931

PARTS NEEDED

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 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.

*******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 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

Group 1 and Group 2

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

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

3. Contact your AVSpare 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.AVS.COM under the ATTACHMENTS tab.

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

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

Group 2 Only - See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
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 AVSpare 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.AVS.COM under the ATTACHMENTS tab or contact your AVSpare 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.

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-70000 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 AVSpare 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.AVS.COM under the ATTACHMENTS tab or contact your AVSpare 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.
 
 

Information System:

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