PRODUCT SUPPORT PROGRAM FOR SALVAGING THE FRONT SUSPENSION CYLINDER ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR SALVAGING THE FRONT SUSPENSION CYLINDER ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE8424-02

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12Nov2018

(Revised 09May2019)

N030
N061
N184
N18C
N18D
N18F

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR SALVAGING THE FRONT SUSPENSION CYLINDER ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS
7201		PS53889

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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 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 "PS53889" 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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NOTE:	This Revised Service Letter replaces the 12Nov2018 (Revised 20Nov2018) Service Letter. Changes have been made to the Problem, Affected Product, Parts Needed, and Action Required.

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TERMINATION DATE

30Nov2020

PROBLEM

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The existing 430-9719 front suspension cylinder (included in the 435-2928 Oil Sands Front Suspension Gp) can fail due to flaking of the AST coating on the rod surface at the lower bushing interface on certain 797, 797B, 797F Off-Highway Trucks. If the existing rod coating fails it can cause damage to the base material of the rod, failure of seals, damage to the suspension housing, and loss of suspension charge pressure.

AFFECTED PRODUCT

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Model	Identification Number
797	5YW00197-00198, 200-201, 204-205, 208-209, 213-218, 221-222, 240, 244-245, 247-250, 254-255, 262-265, 269
797B	JSM00123, 127-128, 130-131, 135-136, 139-142, 144-149, 152-164, 191-194, 206-212, 216-217, 219-228, 236-238, 244, 256, 261, 265-267, 276-279, 291, 296, 298, 302-303, 308, 311-317, 320-332, 338-353, 364-365, 369-382, 385-389, 393-395, 398-402, 404-409, 412-413, 415, 418, 422, 424, 426, 430, 432, 434-439, 446, 449-451, 453, 456-457, 461-462, 472, 476-488
797F	LAJ00142-00144, 189, 200-203, 227-228, 251-255, 262, 264, 266-269, 276, 283, 285, 287, 292-293, 295-296, 303, 308, 311-314, 316-322, 327-328, 341, 343-344, 350-351, 365, 372-373, 445-446, 458-461, 464-466, 468, 476-477, 483, 491-494, 507-512, 523-525, 554-561, 569-571, 573-584, 596, 634-636, 639, 642-643

PARTS NEEDED

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Qty	Part Number	Description
12	8C4032	NUT-HEX (Note A)
1	8H0273	SEAL-O-RING (Note A)
8	8T1583	NUT-HEX (Note A)
8	9X8399	WASHER (Note A)
8	1078425	BOLT-HEX HEAD (Note A)
12	1461799	WASHER-HARD (Note A)
1	1490811	RING-WEAR
1	1490812	RING-WEAR
1	1490813	RING-WEAR
3	1492695	SEAL-O-RING
5	1492696	RING-BACKUP
8	2179902	WASHER-HARD
12	2179903	WASHER-HARD
12	2248961	BOLT-HEX HEAD
1	3124255	SEAL-U-CUP
1	3124259	SEAL-WIPER
1	3743464	SEAL-U-CUP
1	4597518	RING-BACKUP (Note B)
1	5255270	ROD (If required) (Note C)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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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The rod surface should be inspected during the daily walk around. Replace the front suspension immediately upon signs of AST flaking and/or cracking. Failure to take immediate action will increase repair cost and prevent the rod from being salvaged.

Note A: If Equipped with standard suspension mounting hardware. If the machine is equipped with Superbolts, they should be cleaned, inspected, and replaced as required.

Note B: The 149-0813 Bushing must be used during the repair. If the housing has a two groove configuration, it must be reworked per REHS2099 under the Housing Type D Required Dimensions listed under housing part number 185-3150.

Note C: If the rod cannot be salvaged, refer to Image 1.1 for the appropriate allowance for replacement of the rod based upon rod SMU.

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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%
0-8000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-12000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
12001-16000 hrs, 25-30 mo	0.0%	25.0%	0.0%	0.0%	75.0%	75.0%
16001-18000 hrs, 31-36 mo	0.0%	0.0%	0.0%	0.0%	75.0%	100.0%

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NOTE: This is a 103.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
To claim this program, the dealer and/or customer must maintain records of inspections of the rod suspension surface during every planned maintenance (PM). Allowances provided are for salvage costs of the suspension cylinder. If the rod cannot be salvaged, refer to Image 1.1 for the appropriate allowance for replacement of the rod based upon rod SMU. Note: 81.0 hours is allowed to remove and install the front strut. Note: 22.0 hours is allowed to disassemble and assemble the front strut. Note: An additional 11.0 hours is allowed if a 148-9789 Steel Piston needs to be chrome plated to become 514-3993. Note: Part age/hours only applies if there was a previous repair in which the customer participated. A copy of the Site Failure Report or Site Observation Report must be uploaded with the claim.