PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT SUSPENSION CYLINDERS ON CERTAIN 775G OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT SUSPENSION CYLINDERS ON CERTAIN 775G OFF-HIGHWAY TRUCKS

Usage:

TEBE9204-00

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15May2019

M610

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT SUSPENSION CYLINDERS ON CERTAIN 775G OFF-HIGHWAY TRUCKS
7201		PS90969

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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 Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90969" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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

30Nov2019

PROBLEM

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The existing front suspension cylinder can fail when the suspension rod makes contact with the suspension housing on certain 775G Off-Highway Trucks. If the suspension rod makes contact with the suspension housing, it will result in delamination of the HVOF coating of the rod causing the suspension cylinder to leak and collapse.

AFFECTED PRODUCT

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Model	Identification Number
775G	RFM00439-00440, 560-563, 571, 577, 604, 616-617

PARTS NEEDED

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Qty	Part Number	Description
2	0R3691	ROD
2	1H8278	SEAL-O-RING
4	1K6853	FITTING-RELIEF
1	1U9891	ADDITIVE-OIL
4	2H5001	SEAL-O RING
2	3B8489	ADAPTER-STR
2	3J1907	SEAL-O-RING-STOR
2	5J6444	RING-BACKUP
2	5J9451	BEARING
2	5M6214	PLUG-NPTF
2	6C3214	BOLT
2	7D2878	SHIM
1	7X7664	GREASE-MP
4	8T1127	RING-WEAR
2	8T7692	RING-WEAR
2	8T7695	RING-WEAR
2	9X7333	SEAL-LIP TYPE
2	2234720	PLATE-STRUTS
4	2792269	FILM-WARN
4	2792271	PLATE-WARN
2	3844371	SEAL-U-CUP
2	3844374	RING-BACKUP
4	4335903	SEAL-U-CUP
2	4394503	RING-BACK UP
2	4519205	HOUSING AS-MACH
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 25% 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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When one suspension cylinder fails on the machine, rework both suspension cylinders.

Refer to the attached Rework Procedure.

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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%
0-16000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 24.0-hour job

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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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Replace the 334-4222 Suspension Housing used in the 334-4225 Suspension Group with a new 451-9205 Suspension Housing Assembly.

The 451-9205 Suspension Housing Assembly has added an additional 439-4503 Back-Up Ring and 8T-1127 Wear Ring to improve the performance of the suspension group. For the Rework Procedure, refer to KENR9969, Disassembly and Assembly, "Tire and Rim (Front) - Remove and Install", "Front Suspension (Cylinder) - Remove and Install", and "Spindle (Front) - Remove and Install".

Refer to REHS4445, Special Instruction, "Servicing the Suspension Cylinders for Off-Highway Trucks", for the charging procedure for the front suspension groups.

If the 271-7477 Rod is found to have failed because of rod to housing contact, attach a picture of the failed 271-7477 Rod to the SIMS claim. If the rod can not be salvaged, replace it with a 0R-3691 Rod (remanufactured).

1. During disassembly of the strut and before the rod is disconnected from the spindle housing mark both components in relation to their orientation to each other. Refer to Image1.1.1. Inspect the rod surface for any defects and if the 271-7477 Rod is found to be defect free, replace the existing 334-4222 Suspension Housing with a new 451-9205 Suspension Housing Assembly and reuse the 271-7477 Rod. During reassembly of the rod to the spindle housing, position the orientation markings, that were made before separation of the rod from the spindle housing, 180 degrees away from each other. Refer to Image1.1.2.

Image1.1.1

Image1.1.2

2. Reuse and install the components from the existing 334-4222 Suspension Housing that are not provided in the Parts Needed into the new 451-9205 Suspension Housing Assembly. Install the new components provided in the Parts Needed into the new 451-9205 Suspension Housing Assembly in order to complete the Rework Procedure.

If reworking the 441-5252 Front Strut Housing with a 451-9205 Housing, use the 384-4371 U-Cup Seal and the 384-4374 Back-Up Ring. Refer to Image1.2.2.

The 433-5903 U-Cup Seal opening needs to face the pressure cavity of the front suspension group and the 439-4503 Back-up Ring needs to be installed on the grease cavity side of the back-up ring. Refer to Images1.2.4 and 1.2.2.

3. Install all required warning films on the 451-9205 Suspension Housing Assembly. Refer to Image1.2.1.

4. Record the serial number for each 451-9205 Suspension Housing on the SIMS claim. Refer to Image1.2.3 for the location.