PRODUCT SUPPORT PROGRAM FOR REPLACING THE 461-7560 AND 461-7561 HOSE ASSEMBLIES ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 461-7560 AND 461-7561 HOSE ASSEMBLIES ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS
Usage:
TEBE8344-00
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17Dec2018
U-724
A-523
D-640
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Before/After
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 461-7560 AND 461-7561 HOSE ASSEMBLIES ON CERTAIN 794 AC OFF-HIGHWAY TRUCKS
7755 5057
PS46087
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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 "PS46087" 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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TERMINATION DATE
31Dec2020
PROBLEM
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The existing hose assemblies can fail on certain 794 AC Off-Highway Trucks.
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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 14% 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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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
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-12000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 3.0-hour job for Group 1
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-12000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 3.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Remove existing 461-7560 Hose As on truck and two rail nuts (A), two half clamps (B), one cover plate (C), two washers (D) and two bolts (E) at eight locations marked X as shown in Images 1.6.1 through 1.6.4. Remove 461-7561 Hose As on truck and two rail nuts (A), two half clamps (F), one cover plate (C), two washers (D) and two bolts (E) at location marked Y as shown in Image 1.7.1. The hose assemblies will not be reused. Retain all other removed parts for reuse later.
Note: For trucks MT500112 through MT500120, the half clamps (B) and half clamps (F) will not be reused.
2. Locate and weld 8X-5963 Block (1) to underneath side of drive pump mounting bracket assembly with a 3 millimeter (0.12 inch) fillet weld all around block as shown in Image 1.2.1.
Image1.2.1
3. Attach 570-3585 Hose As (2) to the low pressure pump port on the hose control valve using one 228-7089 Seal O-Ring (4). Attach 570-3586 Hose As (3) to pressure valve on hoist control valve using one 228-7089 Seal O-Ring (4).
Image1.3.1
4. Attach 242-8024 Bracket As (5) to 8X-5963 Block (1) using one 8T-4192 Bolt (6) and one 5P-1076 Washer (7) as shown in Image 1.4.1. Tighten bolt 100 +/- 20 Nm (74 +/- 15 lb ft). Secure 570-3586 Hose As (3) to 242-8024 Bracket As (5) using one 8T-1889 Clip (8), one 8T-1890 Clip (9), one 6V-0826 Grommet (10), one 8T-4195 Bolt (11) and one 8T-4121 Washer (12) as shown in Images 1.4.1 and 1.4.2. Leave bolt loose.
Image1.4.1
Image1.4.2
5. Attach 242-8024 Bracket As (5) to 8X-5963 Block (1) using one 8T-4192 Bolt (6) and one 5P-1076 Washer (7) as shown in Image 1.5.1. Tighten bolt 100 +/- 20 Nm (74 +/- 15 lb ft). Secure 570-3586 Hose As (2) to 242-8024 Bracket As (5) using one 8T-1889 Clip (8), one 8T-1890 Clip (9), one 6V-0826 Grommet (10), one 8T-4195 Bolt (11) and one 8T-4121 Washer (12) as shown in Images 1.5.1 and 1.4.2. Leave bolt loose.
Image1.5.1
6. Secure 570-3585 Hose As (2) to frame at eight locations marked X using two rail nuts (A), two half clamps (B), one cover plate (C), two washers (D) and two bolts (E) that were saved in Step 1. Reference Images 1.6.1 through 1.6.4.
Note: For trucks MT500112 through MT500120 replace two half clamps (B) with two 517-5505 Half Clamps (13) at eight locations marked X.
Image1.6.1
Image1.6.2
Image1.6.3
Image1.6.4
7. Secure 570-3586 Hose As (3) to frame at location marked Y using two rail nuts (A), two half clamps (F), one cover plate (C), two washers (D) and two bolts (E) that were saved in Step 1.
Note: For trucks MT500112 through MT500120 replace two half clamps (F) with two 468-9700 Half Clamps (14) at location marked Y.
Image1.7.1
8. Attach 570-3585 Hose As (2) to the superstructure bulkhead plate using one 228-7089 Seal O-Ring (4). Attach 570-3586 Hose As (3) to steering flow amplifier valve using one 228-7089 Seal O-Ring (4).
Adjust hose assembly routings to prevent hose assemblies from rubbing on other hose assemblies in surrounding area.
Tighten 570-3585 Hose As (2) at low pressure pump port on the hoist control valve to 25 +/- 2 Nm (221 +/- 18 lb in). Tighten other end of hose assembly at superstructure bulkhead plate to 15 +/- 2 Nm (133 +/- 18 lb in).
Tighten 570-3586 Hose As (3) at pressure valve on the hoist control valve to 25 +/- 2 Nm (221 +/- 18 lb in). Tighten other end of hose assembly at steering flow amplifier valve to 45 +/- 4 Nm (398 +/- 35 lb in).
Image1.8.1
Image1.8.2
9. Tighten two bolts (E) at eight locations marked X and one location marked Y to 12 +/- 2 Nm (106 +/- 18 lb in). Tighten two bolts (11) on underneath side of drive pump mounting bracket assembly to 12 +/- 2 Nm (106 +/- 18 lb in).
