PLATFORM GP 4367097 - Caterpillar

TERMINATION DATE
31Jan2013
PROBLEM
775F Flat Floor Truck bodies have exhibited evidence of accelerated wear and deformation in certain applications, requiring extensive rework to reinforce the truck body structure. If the problem isn't attended to in a timely manner, irreparable damage could occur.
AFFECTED PRODUCT
Model Identification Number
775F TRUCK BODY FHE00166, 255, 412, 419, 555
PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
If upon inspection of the truck body there are visible signs of damage, the body will need to be reworked as per the recommended rework procedure stated below.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-15000 hrs,
0-72 mo 100.0% 0.0% 0.0% 100.0% 0.0% 0.0%
This is a 0.0-hour job
This programme covers miscellaneous expenses only, capped at 15,000Euro (19,685USD) in total per machine, to cover dealer subcontracted invoices for reinforcement of the body. All other labour related expenses are to be absorbed by the dealer. No itemized parts are required to perform this repair.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
This repair procedure only applies to 277-3200 Flat Floor Truck bodies as used on 775F Small Off Highway Trucks.
- Remove remainder of factory floor liner
Remove current liners. Cut out existing damaged liner plates from the truck body floor. Carry out repairs to the floor plate as necessary to enable the new liner plates to be sufficiently supported
- Remove sidewall sections between vertical support ribs
Cut out side wall window plates. Assess the level of damage to the Left and Right side inner and outer side walls of the body. Depending upon the severity of damage only 2 window plates may need to be cut out on either side. Cut out the damaged window plates as required from the left and right sides of the body Re-welding of floor rips.
- Replace floor liner with 25mm 400HBN liner
Cut new liner plates from 25mm 400HBN steel plate as per supplied instructions (sections according to floor deformation) Align the various plates, tack weld in position. Check and reset as necessary the the plate heights to ensure a uniform level across the complete floor. Weld all floor plates into final position.
- Install 16mm 400HBN liner on sidewalls.
Cut new inner body liner plate from 16mm 400HBN steel plate (3 pieces)
Tack weld into position and check for uniform alignment prior to final welding.
- Install 6mm cover plates on outside of sidewalls.
Cut new outer body window plates from 6mm steel plate.
Replace outer side windows with 6mm steel plates.
- Install 12mm front wall liner according to factory dimensions.
Cut a new Front wall body liner plate from 12mm 400HBN steel plate.
Locate and weld in position.
- Repair floor rib and miscellaneous cracks on body and paint exterior.
Inspect the body support rib structure on the underside of the body.
Check and repair any cracked welds as required.