PRODUCT IMPROVEMENT PROGRAM FOR CHECKING, TIGHTENING, AND/OR REPLACING THE 8C-3236 RETAINER BOLTS ON CERTAIN 793D, 793F AND 793F XQ OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR CHECKING, TIGHTENING, AND/OR REPLACING THE 8C-3236 RETAINER BOLTS ON CERTAIN 793D, 793F AND 793F XQ OFF-HIGHWAY TRUCKS

Usage:

REBE7880-02

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19Dec2011

(Revised 17Feb2012)

U-567

A-463

D-493

O-499

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR CHECKING, TIGHTENING, AND/OR REPLACING THE 8C-3236 RETAINER BOLTS ON CERTAIN 793D, 793F AND 793F XQ OFF-HIGHWAY TRUCKS
4300 4201 4305		PI31963

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31963" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31963" as the Part Number, "7751" as the Group Number, "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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NOTE:	This Revised Service Letter replaces the 19Dec2011 (Revised 16Feb2012) Service Letter. A change was made to image number in the first paragraph of the Rework Procedure for Group 2.

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COMPLETION DATE	TERMINATION DATE
30Jun2012	31Dec2012

PROBLEM

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The existing 8C-3236 Retainer Bolts for the front spindle to strut retainer of the 2527174 Wheel Group may not be properly tightened on certain 793D, 793F, and 793F XQ Off-Highway Trucks. Also, on these trucks with the extended life brake package, the bolts of the 246-6761 Steering Arm Group mounted at the 183-9580 Steering Arm Group may not have been properly tightened during the torque and turn operation leading to the possibility of loose bolts. If the existing bolted joint fails it can cause undesired wear of the joint components or complete disconnect of the steering arm from the spindle assembly and front strut.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
793D	FDB01441-01451, 1453-1457, 1463-1465, 1467, 1469-1475, 1478-1516
793F	SSP00318, 333-334, 348, 350, 353-354, 375, 384-388
793F XQ	SND00100

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*****Group 2*****
793D	FDB01452, 1458-1462, 1466, 1468, 1476-1477
793F	SSP00313-00317, 319-332, 335-347, 349, 351-352, 355-374, 376-383, 389

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
This Group does not have any parts.
*****Group 2*****
36	8C3236	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 3.0-hour job for Group 2

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 8C-3236 TORQUE TURNED RETAINER BOLTS ON CERTAIN OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 793D and 793F Off-Highway Trucks

Dear Caterpillar Product Owner:

The existing 8C-3236 Bolts of the 246-6761 Steering Arm Group, mounted at the 183-9580 Steering Arm Group may have been improperly torqued on the products listed below. If the existing bolted joint fails it can cause undesired wear of the joint components or complete disconnect of the steering arm from the spindle assembly and front strut. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 19Dec2011 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 19Dec2011 Service Letter

Rework Procedure

Group Number 1

Check the retainer to strut bolt torque. Refer to Image 1.1.1. These bolts do not have a torque turn requirement so they may be checked using a static torque check. The torque that the fastener, threaded connector, etc., shall withstand without movement. Static inspection torque provides an indication that minimum assembly requirements have been achieved. Each bolt should be checked to a static torque of 1400 Nm. If movement is found on any bolt, tighten that bolt to the D&A assembly spec (1600+/-200 Nm). If the bolt does not reach the proper assembly spec, replace that bolt and tighten to the required torque specification(1600+/-200 Nm). If these bolts are found to need replacement, replace one at a time and do not remove or replace any others until the bolt found to be nonconforming per the static torque check has been replaced and re-tightened to the correct torque specification.

Image1.1.1

Group Number 2

The retainer bolts for the spindle to strut retainer may not be properly tightened on certain trucks. On these trucks, with the extended life brake package, the bolts may not have been properly tightened on the torque and turn operation leading to the possibility of loose bolts. The conformance to the torque and turn portions of the tightening procedure cannot be evaluated by a static inspection torque after assembly. Inspect the joint for looseness or damage. Remove and replace the outer ring of 8C-3236 Bolts (1), one at a time. Refer to Image 2.1.1. Reinstall new bolts and flat washers, and tighten to the correct torque following KENR8579, Disassembly and Assembly, "Front Suspension (Cylinder)-Install", Illustration 9, and the torque instruction in Step 8, before proceeding to the next bolt.

Once the outer ring of bolts has been replaced and tightened to the specified torque requirements, you may proceed to the inner ring of bolts (2). Refer to Image 2.1.1. These bolts do not have a torque turn requirement so they may be checked using a static torque check. The torque that the fastener, threaded connector, etc., shall withstand without movement. Static inspection torque provides an indication that minimum assembly requirements have been achieved. Each bolt of the inner circle of bolts should be checked to a static torque of 1400 Nm. If movement is found on any bolt, tighten that bolt to the D&A assembly specification (1600+/-200 Nm). If the bolt does not reach the proper assembly spec, replace that bolt and tighten to the required torque specification (1600+/-200 Nm). If these bolts are found to need replacement, replace that bolt and tighten to the required torque specification. If these bolts are found to need replacement, replace one at a time and do not remove or replace any others until the bolt found to be nonconforming per the static torque check has been replaced and re-tightened to the correct torque specification.