PRODUCT SUPPORT PROGRAM FOR REWORKING THE SERVICE BRAKE OIL FILTRATION SYSTEM ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE SERVICE BRAKE OIL FILTRATION SYSTEM ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS

Usage:

REBE3307-01

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10Oct2008

(Revised 06Feb2009)

U-520

A-431

D-437

O-478

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE SERVICE BRAKE OIL FILTRATION SYSTEM ON CERTAIN 773F AND 775F OFF-HIGHWAY TRUCKS
7755 4257 4263 5068		PS42805

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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 "PS42805" 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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NOTE:	This Revised Service Letter replaces the 10Oct2008 Service Letter. Changes have been made to Affected Product.

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TERMINATION DATE

31Oct2010

PROBLEM

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The existing 1340964/">134-0964 Filter Element can plug on certain 773F and 775F Off-Highway Trucks. If the existing filter element plugs before the scheduled 500 hour service interval it will log a plugged filter event in the machine monitoring system and may cause unscheduled downtime to replace the filter element. The 1340964/">134-0964 Filter Element is part of 1556061/">155-6061 Filter Gp part of 225-8210 Accumulator Lines Gp.

AFFECTED PRODUCT

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Model	Identification Number
773F	EED00273-00862
775F	DLS00275-00821

PARTS NEEDED

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Qty	Part Number	Description
2	1P4577	FLANGE-HALF
1	1S2176	COVER
4	3D2824	SEAL-O-RING
1	3J1907	SEAL-O-RING
3	4J0520	SEAL-O-RING
6	5K9090	SEAL-O RING
1	5P7468	CLIP
1	5P7469	CLIP
1	5P8444	GROMMET
1	6V8714	CONNECTOR-SEAL
1	6V8784	TEE-FACE SEAL
4	6V9746	SEAL-O RING
1	6V9840	TEE-SWIVEL
2	7X3166	ADAPTER-SWIVEL
8	7X7729	WASHER
8	8T4121	WASHER-HARD
4	8T4133	NUT
8	8T4136	BOLT
4	8T4139	BOLT
4	8T4178	BOLT
4	8T4223	WASHER-HARD
1	8T4834	TEE-SWIVEL-ORFS
2	8T6684	ELBOW-90 DEGREE
1	9D2095	BLOCK
3	1305300	CLIP
1	1340964	ELEMENT AS.-HYDR
1	1445194	HOSE AS.
1	1556061	FILTER GP-OIL(H)
1	2807090	PLATE
1	2938255	BRACKET AS.
1	2975605	HOSE AS
1	3288309	HARNESS AS
1	3288781	HOSE AS.
1	3288782	HOSE AS.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-8000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 6.0-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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Refer to the Service Manual if/as necessary.

1. Raise the body until the retaining eyes on the body are aligned with the retaining eyes on the frame. Install the two body retaining pins. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar
products. Dispose of all fluids according to local regulations and mandates.

2. Remove 287-4577 Hose As. (1) by loosening four 5S-7382 Bolts (2) and removing one 1P-4577 Flange (3) on 237-3960 Pump Gp (4) part of 262-4979 Gear Pump Gp. If the machine is equipped with, remove one 8T-4195 Bolt (5), two 7X-7729 Washer (6), one 8T-4133 Nut (7), one 5P-8112 Grommet (8), one 5P-7466 Clip (9), and one 5P-7467 Clip (10) and remove 287-4577 Hose As. (1) at 1556061/">155-6061 Filter Gp. (11). See Image 1.1.1.

Image1.1.1

3. Remove 176-1379 Hose As. (12) at 1556061/">155-6061 Filter Gp. (11). Remove one 8T-4186 Bolt (13), two 8T-4121 Washer (14), one 8T-4133 Nut (7), one 5P-8112 Grommet (8), one 8E-1042 Clip (15), and one 8E-1043 Clip (16) and remove 176-1379 Hose As. (12) at 7X-0873 Tee (17) part of 148-8430 Tee As. part of 274-7854 Accumulator Mounting Gp. See Image 1.2.1 and 1.2.2.

Image1.2.1

Image1.2.2

4. Remove all fittings from 1556061/">155-6061 Filter Gp (11). Remove four 8T-4137 Bolt (18) and four 8T-4121 Washer (14), disconnect 156-1383 Switch As. (19) part of 1556061/">155-6061 Filter Gp. from chassis harness as. and remove 1556061/">155-6061 Filter Gp. (11). See Image 1.3.1.

Image1.3.1

5. Remove 9U-3863 Hose As. (53) or 312-4964 Hose As. (53) at 6V-9007 Elbow (42) part of 148-8347 Elbow As. part of 236-7266 Torque Converter Lines Gp and at 6V-8640 Connector (54) on 281-4029 Tube As. part of 229-2094 Power Train Line Gp. See Image 1.4.1.

Image1.4.1

6. Remove 1556061/">155-6061 Filter Gp mounting block (20) from frame and prep frame area for locating and welding 280-7090 Plate (21). Take the necessary precautions to ensure that surrounding components are protected from damage during removal and installation of 1556061/">155-6061 Filter Gp mounting. Locate 280-7090 Plate (21) using dimensions A and B in Image 1.5.2. Attach 280-7090 Plate (21) to frame with a 6 fillet weld all around. See Image 1.5.1 and 1.5.2.

Image1.5.1

Image1.5.2

7. Remove the 136-7032 Oil Filter Housing part of 1556061/">155-6061 Filter Gp from the machine's original oil filter and replace the 1340964/">134-0964 Filter Element. Install 136-7032 Oil Filter Housing to 136-7033 Base As. part of 1556061/">155-6061 Filter Gp and tighten to 101.7 Nm +/- 10 Nm (75 lb-ft +/- 7 lb-ft).

8. Assemble two 1556061/">155-6061 Filter Gp (11) together using two 3D-2824 O-Ring Seal (22), one 6V-8784 Tee (23), one 6V-9746 O-Ring Seal (24), and one 7X-3166 Adapter (25). Assemble one 6V-9746 O-Ring Seal (24), and one 7X-3166 Adapter (25) to 6V-8784 Tee (23). Assemble one 3D-2824 O-Ring Seal (22) and 9D-2095 Block (26) to 7X-3166 Adapter (25). Assemble one 3D-2824 O-Ring Seal (22) and one 8T-6684 Elbow (27) to 1556061/">155-6061 Filter Gp (11). Leave all fittings loose. See Image 1.7.1.

Image1.7.1

9. Assemble 293-8255 Bracket As. (28) to 280-7090 Plate (21) using four 8T-4139 Bolt (29) and 8T-4223 Washer (30). Tighten four 8T-4139 Bolts to 100 Nm +/- 20 Nm (74 lb-ft +/- 15 lb-ft). Assemble oil filter subassembly to 293-8255 Bracket As. (28) using eight 8T-4136 Bolt (31), eight 7X-7729 Washer (6) and three 130-5300 Clip (32) positioned as shown in Image 1.8.1. Tighten eight 8T-4136 Bolts to 55 Nm +/- 10 Nm (41 lb-ft +/- 7 lb-ft). Tighten 6V-8784 Tee O-Ring Port Seal to 180 Nm +/- 20 Nm (133 lb-ft +/- 15 lb-ft) and two O-Ring Face Seals to 90 Nm +/- 9 Nm (66 lb-ft +/- 7 lb-ft). Position 9D-2095 Block (26) as shown in Image 1.8.1. Tighten two 7X-3166 Adapter O-Ring Port Seals to 180 Nm +/- 20 Nm (133 lb-ft +/- 15 lb-ft). Connect 328-8309 Harness As. (33) to two 156-1383 Switch As. (19) part of 1556061/">155-6061 Filter Gp and chassis harness breakout from Step 4. Assemble 328-8309 Harness As. connections to three 130-5300 Clips (32). See Image 1.8.1 and 1.8.2.

Image1.8.1

Image1.8.2

10. Assemble one 3D-2824 O-Ring Seal (22) and one 6V-8714 Connector (34) to 1556061/">155-6061 Filter Gp (11). Assemble one 5K-9090 O-Ring Seal (35) and one 6V-9840 Tee (36) to 6V-8714 Connector (34). Leave all fittings loose. Assemble 297-5605 Hose As. (37) loosely to 8T-6684 Elbow (27) using one 5K-9090 O-Ring Seal (35). Assemble 297-5605 Hose As. (37) to 6V-9840 Tee (36) using one 5K-9090 O-Ring Seal (35). Position 6V-9840 Tee (36) as shown in Image 1.9.1. Tighten 6V-8714 Connector O-Ring Port Seal to 175 Nm +/- 15 Nm (129 lb-ft +/- 11 lb-ft). Tighten 6V-9840 Tee O-Ring Face Seal to 130 Nm +/- 15 Nm (96 lb-ft +/- 11 lb-ft). Tighten 8T-6684 Elbow O-Ring Port Seal to 175 Nm +/- 15 Nm (129 lb-ft +/- 11 lb-ft). Tighten both ends of 297-5605 Hose As. (37) to 130 Nm +/- 15 Nm (96 lb-ft +/- 11 lb-ft). See Image 1.9.1.

Image1.9.1

11. Assemble 328-8781 Hose As. (38) loosely to 9D-2095 Block (26) using 1S-2176 Cover (39), two 1P-4577 Flange (3), two 4J-0520 O-Ring Seal (40), four 8T-4178 Bolt (41), eight 8T-4121 Washer (14), and 8T-4133 Nut (7). Assemble 328-8781 Hose As. (38) to 237-3960 Pump Gp (4) using one 4J-0520 O-Ring Seal (40) and existing 5S-7382 Bolts (2) and 1P-4577 Flanges (3) from Step 2. Tighten four 8T-4178 Bolts to 55 Nm +/- 10 Nm (41 lb-ft +/- 7 lb-ft). Tighten four 5S-7382 Bolts to 47 Nm +/- 9 Nm (35 lb-ft +/- 7 lb-ft). See Image 1.10.1.

Image1.10.1

12. Remove 7X-0873 Tee (17) part of 148-8430 Tee As. and 6V-9007 Elbow (42) part of 148-8347 Elbow As. both part of 274-7854 Accumulator Mounting Gp. See Image 1.11.1.

Image1.11.1

13. Assemble 8T-6684 Elbow (27) to 228-6815 Accumulator Charging Valve Gp (43) using one 3D-2824 O-Ring Seal (22). Assemble one 8T-4834 Tee (44) to 8T-6684 Elbow (27) using one 5K-9090 O-Ring Seal (35). Leave all fittings loose. Assemble 328-8782 Hose As. (45) loosely to 6V-9840 Tee (36) using one 5K-9090 O-Ring Seal (35). Assemble 328-8782 Hose As. (45) to 8T-4834 Tee (44) using one 5K-9090 O-Ring Seal (35). Clip 328-8782 Hose As. (45) to 282-9499 Hose As. (46) part of 229-2094 Power Train Oil Lines Gp using one 5P-7468 Clip (47), one 5P-7469 Clip (48), one 5P-8444 Grommet (49), and one 8T-4186 Bolt (13), two 8T-4121 Washer (14), one 8T-4133 Nut (7) from Step 3. Tighten 8T-4186 Bolt (13) to 55 Nm +/- 10 Nm (41 lb-ft +/- 7 lb-ft). Tighten 8T-6684 Elbow O-Ring Port Seal to 175 Nm +/- 15 Nm (129 lb-ft +/- 11 lb-ft). Tighten 8T-4834 Tee O-Ring Face Seal to 130 Nm +/- 15 Nm (96 lb-ft +/- 11 lb-ft). Tighten both ends of 328-8782 Hose As. (45) to 130 Nm +/- 15 Nm (96 lb-ft +/- 11 lb-ft). See Image 1.12.1 and 1.12.2.

Image1.12.1

Image1.12.2

14. Remove 6V-3965 Nipple As. (50) and 6V-0852 Cap (51) from 7X-0873 Tee (17) and assemble to 8T-4834 Tee (44) using one 3J-1907 O-Ring Seal (52). Tighten 6V-3965 Nipple As. O-Ring Face Seal to 15 Nm +/- 2 Nm (11 lb-ft +/- 1 lb-ft). See Image 1.11.1 and 1.12.1.

15. Assemble 144-5194 Hose As. (55) to 6V-9007 Elbow (42) part of 148-8347 Elbow As. part of 236-7266 Torque Converter Lines Gp and 6V-8640 Connector (54) on 281-4029 Tube As. part of 229-2094 Power Train Line Gp using two 6V-9746 O-Ring Seal (24). Tighten both ends of 144-5194 Hose As. (55) to 90 Nm +/- 9 Nm (66 lb-ft +/- 7 lb-ft). See Image 1.14.1 and 1.4.1.

Image1.14.1

16. Inspect service brake oil filtration system for any leaks. Observe all hydraulic tank sight gauges in order to ensure that the system is refilled to the proper level. Add fluid as required in accordance with the Operation and Maintenance Manual refill capacities. Remove all tools from machine.