REBE7025

Cerrar SIS
Pantalla anterior
Bienvenido: r120rixt
Producto: NO SE HA ESCOGIDO NINGUN EQUIPO
Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Configuracin: NO SE HA ESCOGIDO NINGUN EQUIPO

Carta de Servicio
PRODUCT SUPPORT PROGRAM FOR INSPECTING THE UPPER SUSPENSION LINKS ON CERTAIN 797,
797, AND 797F OFF!HIGH"A# TRUCKS
N$%ero de %edio !REE7&'(!&& Fec)a de *+,-icaci./ !''0&70'&11 Fec)a de act+a-i2aci./ !''0&70'&11
Cater*i--ar3 Co/4ide/tia- #e--o5

REBE7025-00

22Jul2011

U-294
A-243
D-263
O-258

Before/After

PRODUCT SUPPORT PROGRAM FOR INSPECTING THE UPPER
SUSPENSION LINKS ON CERTAIN 797, 797B, AND 797F
OFF-HIGHWAY TRUCKS
7200 7201 7230 7213 PS43331
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Caterpillar: Confidential Yellow
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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 "PS43331" 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.
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.

TERMINATION DATE
31Jul2014

PROBLEM
The existing upper suspension links may crack and fail on certain 797, 797B,
and 797F Off-Highway Trucks. These suspension links need to be ultrasonically
inspected until removed.

AFFECTED PRODUCT
Model Identification Number
797 5YW00193-00196, 202-203, 210-212, 219-220, 223-239, 241
-243, 246, 251-253, 258-259, 270-277
797B JSM00124-00126, 129, 132-134, 137-138, 143, 150, 152,
165-190, 195-205, 213-215, 218, 229-237, 239-260, 262-
264, 268-275, 280-295, 297, 299-301, 304-307, 309-310,
318-319, 333-337, 354-363, 366-368, 383-385, 390-392,
396-397, 403, 410-411, 414, 416-417, 419-421, 423, 425,
427, 429, 431, 433, 440-445, 447-448, 452, 454-455, 458
-460, 463-471, 473-475
797F LAJ00141, 145-199, 204-226, 229-246
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PARTS NEEDED
Qty
Part Number Description
8 8T0368 BOLT-HEX HEAD
(After Failure
Only)
8 9X8399 WASHER (After
Failure Only)
4 1121579 SEAL-O-RING (After
Failure Only)
4 2940099 COLLET (After
Failure Only)
2 3581398 LINK AS-UPPER
In order to allow equitable parts
availability to all participating dealers,
please limit your initial parts order to
not exceed 29% 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
The 200-0884 and 306-8202 Upper Suspension Links need to be ultrasonically
inspected for cracks on the bottom and top side of the link bores. The upper
link inspections will be repeated until either the link is found to be
cracked and replaced or until the link reaches PCR. At PCR, or if cracked,
the upper link is to be replaced with a new 358-1398 link assembly.

When replacing a cracked upper link, the upper link on the opposite side
should also be removed and replaced with a 358-1398 Upper Suspension Link
Assembly.

This service letter will no longer be applicable to trucks that have new 358-
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1398 upper links. The new 358-1398 Upper Suspension Links do no need to be
inspected.

Failure rates of the former upper links will vary from site to site,
therefore inspection intervals will be identified by LPBU product support,
Caterpillar District Rep and the dealer.

When filing claim information use PD code 56 for inspection. PD Code 96 is to
be used in the event a link failure while the vehicle is in operation. Any
damage that occurs as a result of a failure may be covered in the claim.

Please refer to inspection procedure attached.

SERVICE CLAIM ALLOWANCES
Product smu/age
whichever comes
first
Caterpillar Dealer Suggested Customer Suggested
Parts %
Labor
Hrs%
Parts %
Labor
Hrs%
Parts %
Labor
Hrs%
0-18000 hrs,
0-36 mo
100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
18001-36000 hrs,
37-72 mo
60.0% 100.0% 0.0% 0.0% 30.0% 0.0%
36001-60000 hrs,
73-108 mo
13.0% 100.0% 0.0% 0.0% 65.0% 0.0%
NOTE: This is a 3.0-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.
NOTE: This is a 3 hour job to inspect both links before failure at
predetermined intervals. If a crack is found, an additional 26
hours are allowed to replace both upper links. If a failure
occurs, 26 hours will be allowed to replace both upper links.

NOTE: The intent of this letter is to replace the upper links at
PCR before failure. Caterpillar will not cover the miscellaneous
parts unless there is an actual failure.

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NOTE: At PCR, no labor will be allowed. The coverage of the cost
of the link will be based on parts hours.

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

Rework Procedure

This procedure provides the method used to ultrasonically inspect upper links
for large internal cracks simulated at Integrated Manufacturing Division
(IMOD), Caterpillar Inc. Decatur, IL.
This procedure supersedes any previous Ultrasonic Inspection Procedures
provided on links.
Personnel performing the inspections will be at least Level II Certified
Technicians in the appropriate method, as defined by ASNT SNT-TC-1A
If this procedure must be performed to site safety procedures! Any grinding
operations need to have full face shield, long sleeve shirt, and face mask.
The instrument used for this procedure shall be a Krautkramer 58L or
equivalent flaw detector. The instrument shall have a current record for
having been calibrated for vertical and horizontal linearity per ASTM E317.
The search unit shall consist of a small 45-degree wedge and a .375 (10mm)
diameter 2.25 MHZ transducer.
The couplant shall be Sonotech, Soundclear Grade 60 or equivalent.

Instrument Calibration
Calibrate the instrument for distance using a steel IIW Type 2 Block to a
range of at least 150mm. This should be done using both the 50mm and 100mm
radius.
This velocity will be very close to casting material velocity but not exact.
Set the gate to 15% Full Screen Height.

Calibrate for sensitivity using internal bearing bore surface.
Place the 45deg search unit on the link at location #3. See Figure 4 & 5.
Peak the indication and adjust the gain to 100% Full Screen Height.
Increase the gain +6db and use this gain as the reference level for scanning.
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Inspection Procedure
The bar link shall be made accessible and clean in the areas as shown in
Figures 1 & 3. Any material that would interfere with the transmission of
sound energy from the transducer into the link shall be removed. (Loose Paint,
grease, dirt, oil, etc.)
Using the calibration from above, inspect from the areas shown in Figures 1,
2, and 3.
Inspect from both directions on the bottom of the link as shown in Figure 3.
When the transducer reaches location #3 shown in Figures 4 & 5 a geometry
signal from the inside bearing bore surface will be present. Slowly move the
transducer toward location #2 and #1.
Cracks similar to location #2 on Figure 4 & 5 will be difficult to detect
because of the large change in the surface profile.
Cracks similar to location #1 on Figure 6 will be difficult to detect because
of the angle the sound is propagating compared to the major crack axis.
Additional inspection may need to be preformed from location #3 in on Figure
6.
Geometry indications may appear from the lube hole in Location #3 on Figure 6
but a cracked link indication will have a large amplitude compared to a good
link.

As an Optional Inspection Location in Figure 1 scan from the Optional Scan
direction if the radius if too sharp to maintain coupling.
Caution should be taken when inspecting from the optional location as the vent
holes will cause false indications.

Image1.2.1
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Image1.2.2

Rejection Criteria
Reject any relevant indications that cross the gate at reference level and are
found in the area of concern. See Figures 8, 9, 10 and 11 for examples.

Reference UT Indications
Figure 8 shows the UT indication from a 30mm deep saw cut. Top of Link.
Figure 9 shows the UT indication from a 12mm deep saw cut in the same location
as Figure 8.
Figure10 shows the UT indication from a 12mm deep saw cut. Bottom of Link.
Figure 11 shows the UT indication from a 12mm deep saw cut that connects to
the lube hole on the bottom side of the link.
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Image1.3.1
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Image1.3.2
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Image1.3.3
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Image1.3.4
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Image1.3.5

Please report any rejected upper links to Dealer Technical Communicator for
disposition.
Dealer technical communicator will report findings to Caterpillar district
representative and Ken Minks (Minks_Ken _D@Cat.Com)
Please provide inspection reports as well as pictures with screen information
and transducer location on rejected links.

REFERENCES
ASTM E 317
ASNT SNT-TC-1A

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r120rixt

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