PRODUCT SUPPORT PROGRAM FOR REPLACING THE A-FRAME BEARING AND RELATED PARTS IN THE FRONT SUSPENSION FRAME GROUP OF CERTAIN 735, 740, AND 740EJ ARTICULATED TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE A-FRAME BEARING AND RELATED PARTS IN THE FRONT SUSPENSION FRAME GROUP OF CERTAIN 735, 740, AND 740EJ ARTICULATED TRUCKS

Usage:

REBE7978-01

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09Aug2012

(Revised 27Mar2013)

U-415

A-330

D-355

O-382

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE A-FRAME BEARING AND RELATED PARTS IN THE FRONT SUSPENSION FRAME GROUP OF CERTAIN 735, 740, AND 740EJ ARTICULATED TRUCKS
7113 7203 7050		PS43671

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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 "PS43671" 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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NOTE:	This Revised Service Letter replaces the 09Aug2012 Service Letter. Changes have been made to the Rework Procedure.

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TERMINATION DATE

31Aug2014

PROBLEM

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The 6J-5541 O-Ring seal used in the front suspension frame group of certain 735, 740, and 740EJ Articulated Trucks has a diameter of 3.53 mm. There is insufficient space between the collar (radius) and the a-frame (chamfer) for the O-Ring to fit. This can result in the collar being only partially seated onto the bottom of the a-frame head. In turn, this can allow excess axial float for the outer shell of the spherical bearing.

Insufficient grease purging the joint on machines fitted with Auto-Lube option. Injector sizing does not promote purging of grease through the joint, especially in extreme machine applications.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
735	B1N01280-01295, 1299-1303, 1305-1306, 1308-1312, 1314-1317, 1320-1322, 1324-1341, 1343, 1345-1346, 1350-1351, 1356-1357, 1360-1361, 1365, 1367-1374, 1376-1379
740	B1P04463-04469, 4581-4582, 4956-4957, 4960-4972, 4974-4976, 4979-4984, 4986-5003, 5006-5024, 5026-5030, 5042-5089, 5092-5113, 5115-5130, 5138-5145, 5157-5163, 5167, 5172-5191, 5193-5198, 5200-5201, 5203-5230, 5234-5238, 5245-5256, 5258-5262, 5265-5277, 5281-5284, 5288-5292, 5297-5319, 5321-5343, 5347-5349, 5353-5365, 5369-5383, 5386-5391, 5394-5411, 5413-5427, 5430-5438, 5441-5442, 5444-5481, 5484-5499, 5502-5509, 5513-5520, 5522-5525, 5528-5533, 5536-5563, 5566-5582, 5585-5615, 5617-5624, 5628-5660, 5662-5691, 5693-5698, 5700-5721, 5725-5730, 5732, 5735-5750, 5752-5782, 5784-5789, 5791-5797, 5799-5826, 5828-5830, 5832-5838, 5840-5842, 5847, 5849-5850, 5853-5863, 5865-5867, 5869, 5872-5876, 5879-5904, 5909, 5911, 5913, 5917, 5921, 5923-5924, 5926-5930, 5932-5933, 5935, 5938, 5940-5942, 5945-5946, 5949, 5953-5961, 5963, 5965-5969, 5971-5972, 5974, 5976-5979, 5981, 5987-5991, 5994-6009, 6011-6023, 6026-6028, 6031-6058, 6060, 6062-6065, 6068-6075, 6077-6085, 6087-6093, 6095-6104, 6107-6108, 6110-6123, 6125-6128, 6131-6149, 6151-6170, 6172-6176, 6178-6188, 6190-6192, 6194-6210, 6212, 6214-6216, 6220-6226, 6228-6286, 6288-6295, 6297-6301, 6306-6308, 6310-6311, 6313-6316, 6318, 6321-6322, 6324-6330, 6333-6336, 6339-6350, 6352-6354, 6356-6364, 6367-6377, 6379-6381, 6383-6386, 6391-6392, 6394-6422, 6424-6429, 6431-6445, 6449-6459, 6461-6468, 6470-6512, 6514-6517, 6519-6520, 6522-6537, 6539-6544, 6546, 6551-6572
740 OEM	WWD00474-00477, 479-485
740EJ	B1R00496, 498-499, 501-512, 517-518, 521-522, 525-527, 529, 532-534, 536-538, 541, 544

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*****Group 2*****
735	B1N01296-01298, 1304, 1307, 1313, 1318-1319, 1323, 1342, 1344, 1347-1349, 1352-1355, 1358-1359, 1362-1364, 1366, 1375
740	B1P04462, 4585-4587, 4958-4959, 4973, 4977-4978, 4985, 5025, 5031-5041, 5090-5091, 5114, 5132-5137, 5146-5156, 5164-5166, 5168-5171, 5192, 5202, 5231-5233, 5239-5244, 5257, 5263-5264, 5278-5280, 5285-5287, 5293-5296, 5320, 5344-5346, 5350-5352, 5366-5368, 5384-5385, 5392-5393, 5428-5429, 5439-5440, 5482-5483, 5500-5501, 5510-5512, 5521, 5526-5527, 5535, 5564-5565, 5583-5584, 5616, 5625-5627, 5661, 5692, 5699, 5722-5724, 5731, 5733-5734, 5751, 5783, 5790, 5798, 5827, 5831, 5839, 5843-5846, 5848, 5851-5852, 5864, 5868, 5870-5871, 5877-5878, 5905-5908, 5910, 5912, 5914-5916, 5918-5920, 5922, 5925, 5931, 5934, 5936-5937, 5939, 5943-5944, 5947-5948, 5950-5952, 5962, 5964, 5970, 5973, 5975, 5980, 5982-5986, 5992-5993, 6010, 6024-6025, 6029-6030, 6059, 6061, 6066-6067, 6076, 6086, 6094, 6105-6106, 6109, 6124, 6129-6130, 6150, 6193, 6211, 6213, 6217-6219, 6227, 6287, 6296, 6302-6305, 6309, 6312, 6317, 6319-6320, 6323, 6331-6332, 6337-6338, 6351, 6355, 6365-6366, 6378, 6382, 6387-6390, 6393, 6423, 6430, 6446-6448, 6460, 6469, 6513, 6518, 6521, 6538, 6545, 6547-6550, 6573-6574
740EJ	B1R00494-00495, 497, 500, 513-516, 519-520, 523-524, 528, 530-531, 535, 539-540, 542-543

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3P0647	SEAL-O-RING
3	5P8246	WASHER-HARD
1	5U7151	CAP-GREASE
3	8T0298	BOLT-HEX HEAD
1	9X7358	SEAL-O RING
1	3016946	BEARING-ALIGN
1	3016948	SLEEVE-TAPER
1	3432873	SEAL-BELLOWS
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.
*****Group 2*****
1	3P0647	SEAL-O-RING
3	5P8246	WASHER-HARD
1	5U7151	CAP-GREASE
3	8T0298	BOLT-HEX HEAD
1	9X7358	SEAL-O RING
1	1926212	DOSER NO. 10
1	3016946	BEARING-ALIGN
1	3016948	SLEEVE-TAPER
1	3432873	SEAL-BELLOWS
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 Attached Rework Procedures.
Group 1 covers standard machines.
Group 2 covers machines with factory fitted Auto Lube systems only. Dealer installed Auto Lube systems are not covered.

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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%
*****Group 1*****
0-8000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 6.0-hour job for Group 1

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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%
*****Group 2*****
0-8000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 6.5-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

REWORK PROCEDURE FOR GROUP ONE AND TWO.

Refer to the Service Manual if/as necessary.

1). Park the machine on a hard, level surface. Engage the parking brake.

2). Install the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

3). Use suitable chocks on both sides of the front and rear wheels in order to prevent the machine from moving.

4). Use suitable hydraulic jacks and stands in order to support the front of the machine. See Image 1.1.1

Image1.1.1

Image1.1.2

5). Use suitable hydraulic jack and stands in order to support the front of rear chassis as close to the hitch as possible. Refer to Image 1.1.2

6). Remove the drive shaft between the transfer gear and the front axle differential. Refer to RENR5139 Front Drive shaft ? "Remove and Install".

7). Disconnect the suspension frame from the underside of the articulating hitch and lower the suspension frame clear of the tapered pin. Refer to RENR5140 Front Suspension Frame ? "Remove".

Note: In order to aid disconnection of the suspension frame from the hitch pin, the use of a 334-8414 Forcing Plate may be required.

8). Remove the 301-6946 Bearing and 301-6948 Sleeve from front suspension frame

Image1.2.1

Image1.2.2

Image1.2.3

Installation

9). Clean the mating surfaces of the Collar and A-Frame in order to remove all dirt and corrosion. Refer to Images 1.2.1 and 1.2.2.

Image1.3.1

10). Install the new 301-6946 Bearing and 301-6948 Sleeve into the front suspension frame (2). Refer to RENR5140 Front Suspension Frame - "Install".

11). Install the new 343-2873 Bellows Seal (1) with the 5U-7151 Cap onto the "A" frame head prior to installation. Refer to Image 1.2.3

Note: Make sure that the grease point on the bellows seal is in the correct position. Refer to Image 1.3.1.

12). Before installation, make sure that the taper surface of the taper sleeve in the suspension frame is free from grease and dirt. This must also be dry on installation.

13). Install the front suspension frame using new 8T-0298 Bolts and 5P-8246 Washers. Refer to RENR5140 Front Suspension Frame ? "Install".

Note: The tightening torque, for the 8T-0298 Bolts, is 135 +/- 25 N.m
Note: DO NOT use any type of lubrication to aid installation.

14). Install the drive shaft between the transfer gear and the front axle differential. Refer to RENR5139 Front Drive shaft ? "Remove and Install".

15). Remove the stands and jacks from the front and rear of the machine.

16). Apply grease through the standard grease point and make sure grease is around the bearing. Install the 9X-7358 Seal (3) and 3P-0647 Seal (4) onto the collar (5). Prime cavity in the collar with grease prior to installation.

Note: The 9X-7358 Seal (3) replaces the 6J-5541 O-ring that was previously used. Refer to Image 1.2.3.

17). Install the collar.

18). Pump grease through the standard grease point. The standard grease point will fill the cavity on the underside of the pin. This will lubricate the bearing from the underside and fill any void after the collar was primed.

19). Continue to pump grease until the bellows seal is full. Grease will exit from the reliefs on the top of the seal at this time.

Note: The bellows is clear. The grease will be visible inside the seal cavity.

20). Remove the chocks from the front and rear wheels.

21). Remove the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

Group Number 2

GROUP 2 AUTO LUBE ONLY.
(1) Remove the grease injector from the manifold that is located on the right side of the front chassis. See Image 2.1.1 for location.
(2) Install new 192-6212 Injector.
(3) Purge new injector by pressing the Test Switch on the Auto Lube pump. See Image 2.1.2 for test switch location.
(4) Install the grease line to the injector.