PRODUCT SUPPORT PROGRAM FOR REWORKING THE 300-5670 BODY ON CERTAIN 777D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 300-5670 BODY ON CERTAIN 777D OFF-HIGHWAY TRUCKS

Usage:

REBE9342-00

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25Feb2013

D-70

O-75

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 300-5670 BODY ON CERTAIN 777D OFF-HIGHWAY TRUCKS
7258 7250		PS52397

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52397" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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TERMINATION DATE

28Feb2015

PROBLEM

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The existing 300-5670 Body on certain 777D Off-Highway Trucks can crack at the one third and two thirds joint of the single piece construction. Refer to Image1 in the Action Required. This service letter only applies to bodies fully assembled at the factory.

AFFECTED PRODUCT

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Model	Identification Number
777D	FKR00200-02070

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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This service letter can only be applied to cracks in the one third and two thirds weld joints of the body as shown in Image 1. Any other cracks or damage is not covered. Furthermore, this service letter only applies to bodies fully assembled at the factory. Therefore, this service letter can only be applied to bodies with sequence numbers listed in Image 2. The sequence number is located on the serial number plate found on the front wall of the body. All claims must include the full sequence number (A2601C1-XXX or A2917J0-XXX where XXX is the body sequence number) in the claim story to be paid. The claim must be filed against the truck serial number on which the body is installed.

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Image1

Image2

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%
0-24000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 20.0-hour job
NOTE: Up to 20 hours can be claimed for this job. Only actual hours used should be claimed. The claim must be filed against the truck serial number on which the body is installed.

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PARTS DISPOSITION

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

Rework Procedure

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Refer to special instruction REHS1841-General Welding Procedures

REWORK PROCEDURE:-

1.Grind and Remove the defective weld(crack).

Note: Use caution when excavating crack. Complete excavation of crack should not be required beyond the 10 mm parent material depth. Do not excavate into the internal steel backing strip.

2. Ensure complete removal of crack at reworked area with Dye Penetrant.

3. Dry the electrodes to 300 ? 350 ? C for 1 hour minimum.

4. Weld the Root with 3.15 mm dia E7018 electrode.

5. Check Soundness of Root weld with DP and ensure welding free from weld defects.

6. Continue furthur welding by E7018 Electrode.

7. Ensure proper cleaning of slag between passes.

8. Complete the weld for all cracked joint by the above process.

9. Ensure final weld surface is free from visual defects.