PRODUCT SUPPORT PROGRAM FOR INSPECTION OF THE MID-FRAME AREA ON CERTAIN 793F, 793F XQ, 793F AC, AND 793F CMD OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTION OF THE MID-FRAME AREA ON CERTAIN 793F, 793F XQ, 793F AC, AND 793F CMD OFF-HIGHWAY TRUCKS

Usage:

TEBE3457-03

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05Aug2015

(Revised 23Aug2017)

U-414

A-296

D-350

O-356

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSPECTION OF THE MID-FRAME AREA ON CERTAIN 793F, 793F XQ, 793F AC, AND 793F CMD OFF-HIGHWAY TRUCKS
7050 7587 7051 0679		PS44823

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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 "PS44823" 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 05Aug2015 (Revised 22Mar2016) Service Letter. Changes have been made to the Termination Date, Affected Product, Service Claim Allowance, and Rework Procedure.

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TERMINATION DATE

31Jan2020

PROBLEM

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Frame cracking has been reported in multiple locations on the mid-frame area of certain 793F, 793F XQ, 793F AC and 793F CMD Off-Highway Trucks. Cracking has been reported on machines that have completed the rework outlined in Special Instruction REHS7995 Procedure to Inspect and Repair the Center Section Frame on Certain 793F Off-Highway Trucks as well as machines that have not completed this rework procedure. Crack initiation sites have been identified on the 4 bar to main rail joints, torque tube to window plate/cover plate, inner and outer window plate attachments and stamped volcano plate. Cracks that go unidentified or identified and left unattended can lead to invasive frame repairs and/or severe frame damage.

AFFECTED PRODUCT

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Model	Identification Number
793F	SSP00112, 114-123, 129-162, 164-170, 173-176, 178-181, 184, 186-189, 191-196, 198, 205, 211, 213-242, 247, 249-254, 257-260, 262-270, 272-305, 308-318, 320-344, 346-351, 353-355, 357-361, 364-365, 367-374, 377-396, 398-399, 402-422, 424-452, 454, 456-459, 461-466, 469, 471-475, 477-478, 480-483, 486, 490-499, 501-509, 511-526, 529-547, 549-558, 560, 562-564, 566-571, 573-588, 591-593, 595-602, 604-612, 614-650, 652-684, 686, 688-694, 696-701, 703-706, 710, 714-719, 721, 723, 726, 728-729, 732-734, 736-740, 742-744, 746-747, 749-751, 753, 755, 757-758, 761-770, 773-775, 777-780, 782, 785, 788-791, 796-799, 802, 804-832, 834-836, 838-839, 841-848, 852-864, 866, 868, 870-875, 877-878, 883, 889-898, 901-943
793F CMD	RBT00111-00122, 126-131, 133-136, 138-140, 142-164
793F XQ	SND00101, 104, 106-109, 111-116, 118, 120-121, 125-129

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Inspect the Off-Highway Truck according to the attached Rework Procedure. As directed in the rework procedure, the areas of interest on the frame must be cleaned with an appropriate high pressure washer prior to inspection. Refer to the Weld Inspection and Acceptance Criteria, Table 9, located in Special Instruction REHS7193 or Table 10, located in Special Instruction REHS7995 for the applicable inspection acceptance criteria.

Note: This inspection does not take the place of the complete frame inspection that is part of the 500 service hours or 3 months preventative maintenance interval as stated in the machines Operation and Maintenance Manual. Special Instruction REHS7193 provides detail on the required full frame inspection.

A crack found at inspection should be marked and dated with paint/etch in order to easily identify any crack growth at a future inspection. Provide a digital photo of the crack and the visible length of crack in millimeters. Please make certain digital photos provide sufficient detail to identify the crack location on the frame as well as a clear view of the crack. Multiple photos of each crack are permissible. The crack should also be documented in the attached checklist.

Note: An inspection form has been created utilizing the Cat Inspect App for the mid-frame area. Inspection form: "793F (SSP, RBT, SND, EMD) 12 Gusset Mid-Frame Inspection" has been created specifically for this service letter. Please reference the following web site for more information on Cat Inspect: https://dealer.cat.com/cda/alias/catinspect

If not utilizing the Cat Inspect App inspection form "793F (SSP, RBT, SND, EMD) 12 Gusset Mid-Frame Inspection" the results of the inspections, including the completed checklist and details of any cracks identified (pictures of the crack) should be attached to SIMSi when submitting the warranty claim and emailed to Jay Perry at perry_jay_a@cat.com.

Note: If no cracks are found only the completed checklist is required to be submitted to SIMSi and emailed to perry_jay_a@cat.com.

If utilizing the Cat Inspect App inspection form (793F (SSP, RBT, SND, EMD) 12 Gusset Mid-Frame Inspection) please sync the completed inspection and reference that the Cat Inspect App was used to complete the inspection in the warranty claim story.

Specific recommendations, dependent upon what is found and the information provided, will be provided for all cracks that are reported.

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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%
0-60000 hrs, 0-120 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job
Begin applying this letter at the next available scheduled maintenance interval. Repeat this inspection and supply the required documentation approximately every 2000 service hours thereafter. The letter may be claimed each time the machine is inspected while this letter is open or until the center tube is replaced per special instruction M0069982. Reasonable travel and mileage will be allowed. It is the expectation that multiple machines will be planned for inspection when scheduling the inspections. If utilizing the Cat Inspect App inspection form (793F (SSP, RBT, SND, EMD) 12 Gusset Mid-Frame Inspection) please sync the completed inspection and reference that the Cat Inspect App was used to complete the inspection in the "Comments Section" of the warranty claim story. If not utilizing the Cat Inspect App inspection form (793F (SSP, RBT, SND, EMD) 12 Gusset Mid-Frame Inspection) the results of the inspections, including the completed checklist and details of any cracks identified (pictures of the crack) should be attached to SIMSi when submitting the warranty claim and emailed to Jay Perry at perry_jay_a@cat.com. Note: If no cracks are found only the completed checklist is required to be submitted to SIMSi and emailed to perry_jay_a@cat.com.

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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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General Notes: This procedure applies to the inspection of the center section of the frame. For full frame inspection refer to your machines Operation and Maintenance Manual and Special Instruction REHS7193.

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Clean

The mid-frame section of the frame should be thoroughly cleaned to ensure a quality visual inspection can be completed. Use an appropriate degreaser to remove any oil or grease from the frame. A wire brush or scraper to remove excessive dirt and grease may also be required. It is essential that the area behind the fuel and hydraulic tank is clean.

Inspection

Note: It is required to use a telescopic mirror to visually inspect the welds in certain areas. It is the responsibility of the inspector to utilize a telescopic mirror when the complete weld cannot be inspected.

Note: It is required to use a ladder, step ladder, suitable manlift, and/or access to the top of the main rails to complete this inspection.

Note: Cracks can be difficult to detect. Visual indications should be confirmed by removing the paint and utilizing dye penetrant or magnetic particle testing.

Note: In order to complete the inspection it is required to have the body in the fully raised position with the body retaining cables installed.

Note: It is a best practice to utilize a fillet weld gauge to detect undersized welds. Undersized fillet welds should be documented in the checklist and closely monitored at future inspections. Refer to Special Instruction REHS7995 for the correct fillet weld size in the mid-frame section.

Image1.2.1

Outside Left

Using the Outside Left graphic as a guide visually inspect the following locations on the outside left for cracks or other visual defects.

Starting at the front of the outside left mid-frame section and working towards the back of the frame inspect the:

-Vertical Weld ? Visually inspect full vertical length of the weld joint on window plate.

-Attachment welds ? Visually inspect weld on all sides of the attachments.

-Tank Mounts front fuel tank - Visually inspect weld on all sides of the tank mount.

-Horizontal Weld top and bottom - Visually inspect full horizontal length of the top and bottom weld on window plate.

-Tube Welds inside and outside diameter ? Visually inspect 360 degrees of the inside and outside tube weld diameter.

Note: Access to the top of the main rail will be required to complete the inspection.

Note: It is required to use a telescopic mirror to visually inspect the complete circumference of these welds.

-C Weld ? Visually inspect complete C weld.

-Top Four Bar to Main Rail Weld ? Visually inspect complete weld joint. Pay close attention to the inner and outer corners of the joint. Cracks will typically start at either the inner or outer corner.

Note: Access to the top of the main rail will be required to complete the inspection.

-Bottom Four Bar to Main Rail Weld - Visually inspect complete weld joint. Pay close attention to the inner and outer corners of the joint. Cracks will typically start at either the inner or outer corner.

Image1.3.1

Inside Left

Using the Inside Left graphic as a guide visually inspect the following locations on the inside left for cracks or other visual defects.

Starting at the front of the inside left mid-frame section and working towards the back of the frame inspect the:

-Attachment welds - Visually inspect weld on all sides of the attachments.

-Vertical Weld ? Visually inspect full vertical length of the weld joint on window plate.

-Horizontal Weld top and bottom - Visually inspect full horizontal length of the top and bottom weld on window plate.

-C Weld ? Visually inspect complete C weld.

Image1.4.1

Outside Right

Using the Outside Right graphic as a guide visually inspect the following locations on the outside Right for cracks or other visual defects.

Starting at the front of the outside right mid-frame section and working towards the back of the frame inspect the:

-Vertical Weld ? Visually inspect full vertical length of the weld joint on window plate.

-Attachment welds ? Visually inspect weld on all sides of the attachments.

-Tank Mounts front hydraulic tank - Visually inspect weld on all sides of the tank mount.

-Horizontal Weld top and bottom - Visually inspect full horizontal length of the top and bottom weld on window plate.

-Tube Welds inside and outside diameter ? Visually inspect 360 degrees of the inside and outside tube weld diameter.

Note: Access to the top of the main rail will be required to complete the inspection.

Note: It is required to use a telescopic mirror to visually inspect the complete circumference of these welds.

-C Weld ? Visually inspect complete C weld.

-Top Four Bar to Main Rail Weld ? Visually inspect complete weld joint. Pay close attention to the inner and outer corners of the joint. Cracks will typically start at either the inner or outer corner.

Note: Access to the top of the main rail will be required to complete the inspection.
-Bottom Four Bar to Main Rail Weld - Visually inspect complete weld joint. Pay close attention to the inner and outer corners of the joint. Cracks will typically start at either the inner or outer corner.

Image1.5.1

Inside Right

Using the Inside Right graphic as a guide visually inspect the following locations on the inside right for cracks or other visual defects.

Starting at the front of the inside right mid-frame section and working towards the back of the frame inspect the:

-Pump Box Welds - Visually inspect weld on all sides of the pump box. Pay close attention to the four corners on the pump drive box. Cracks will typically start at the corners of the pump drive box.

-Vertical Weld ? Visually inspect full vertical length of the weld joint on window plate.

-Horizontal Weld top and bottom - Visually inspect full horizontal length of the top and bottom weld on window plate.

-C Weld ? Visually inspect complete C weld.

Image1.6.1

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Top / Bottom

Using the Top View / Bottom View graphic as a guide visually inspect the following locations on the top / bottom for cracks or other visual defects.

-Tube to Stamping Fillet Weld - Left - Visually inspect 360 degrees of the tube to stamping plate weld diameter.

-Tube to Stamping Fillet Weld - Right - Visually inspect 360 degrees of the tube to stamping plate weld diameter.

- Frame and Body Support Pad -Main Rail and Body Rocker Pad (Not Shown) Contact? Left ? Visually inspect the main rail and body rocker pad surface for damage or uneven surface contact wear. If any defects are found it is recommended that the issue is rectified and the body support pads are re-shimmed.

- Frame and Body Support Pad -Main Rail and Body Rocker Pad (Not Shown) Contact? Right ? Visually inspect the main rail and body rocker pad surface for damage or uneven surface contact wear. If any defects are found it is recommended that the issue is rectified and the body support pads are re-shimmed.

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Note: Fill in all areas of the checklist and refer to any applicable pictures that are taken of the affected area.

If you would like the above checklist in a Micosoft Word or Excel format please email the request to: perry_jay_a@cat.com

Note: If Cracking is found in the center tube parent material, plate (Volcano), through the rail thickness or if there are multiple crack initiation sites in the mid frame area submit a DSN (Dealer Solution Network) ticket and reference Service Letter TEBE3457