PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE POWERTRAIN COOLING HOSE ON CERTAIN 777F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE POWERTRAIN COOLING HOSE ON CERTAIN 777F OFF-HIGHWAY TRUCKS

Usage:

REBE4402-02

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24Nov2008

(Revised 31Mar2009)

U-598

A-495

D-510

O-549

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE POWERTRAIN COOLING HOSE ON CERTAIN 777F OFF-HIGHWAY TRUCKS
1375		PI31585

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31585" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31585" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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 24Nov2008 (Revised 22Dec2008) Service Letter. Changes have been made to the Parts Needed.

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COMPLETION DATE	TERMINATION DATE
31May2009	30Nov2009

PROBLEM

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The powertrain cooling hose needs to be replaced on certain 777F Off-Highway Trucks. The existing powertrain cooling hose can rupture or burst on certain 777F Off-Highway Trucks. If the existing hose fails it can result in loss of coolant and unscheduled down time repair.

AFFECTED PRODUCT

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Model	Identification Number
777F	JRP00277-00757, 759-783, 785-945, 947-959, 962, 965-970, 972-976, 978-1160, 1162-1686
777F OEM	JXP00100-00112 WTK00105-00117

PARTS NEEDED

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Qty	Part Number	Description
1	2M1395	GASKET
1	6V1581	CLIP-2 PIECE
1	6V1582	CLIP-2 PIECE
1	7X7729	WASHER
1	8T4172	BOLT
16	8T4984	CLAMP-BAND
1	9R2613	BOSS
1	1997854	SPACER
1	3229716	TUBE
1	3236271	TUBE
2	3249860	HOSE
2	3262945	HOSE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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****Parts Stock ****

Remove all 254-7304 Hoses and 300-8630 Hoses from dealer parts stock.

****Affected Product****

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE POWERTRAIN COOLING HOSE ON CERTAIN 777F OFF-HIGHWAY TRUCKS

MODELS INVOLVED - CERTAIN 777F OFF-HIGHWAY TRUCKS

Dear Caterpillar Product Owner:

The powertrain cooling hose needs to be replaced on the products listed below. The existing powertrain cooling hose can rupture or burst resulting in loss of coolant and unscheduled down time repair. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 24Nov2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 24Nov2008 Service Letter

Rework Procedure

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Drain the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change"
Remove the 300-8630 Bottom Transmission Cooler Hose by removing (2) 208-6054 T-bolt Clamps. Remove and Replace the 2M-1395 Gasket and rotate the 191-9307 Elbow 90 degrees counter clockwise to allow for new material to be assembled.
SPECIAL NOTE: If your truck was assembled with the 254-7307 Bottom Transmission Cooler Hose the 191-9307 Elbow will not need to be relocated. It is already in the correct location.
Weld the 9R2613 boss to the engine support as per image 1.1.3
Refer to Image 1.1.1, 1.1.2 & 1.1.3

Image1.1.1

Image1.1.2

Image1.1.3

Assemble the 323-6271 Tube to the bottom port on the oil cooler with (1) 326-2945 Hose and (4) 8T4984 Clamps. Assemble the other end of the 323-6271 Tube to the front top port of the oil cooler on the engine with (1) 326-2945 Hose and (4) 8T4984 Clamps.
Note: The torque for the 8T4984 Clamp is 12 +/- 1 NM (5/16" HEX)
Connect the (1) 6V1581 & 6V1582 Clip to the 323-6271 Tube and connect to boss on Engine Support with (1) 8T4172 Bolt, (1) 7X7729 Washer and (1) 199-7854 Spacer as per image 1.2.4
Refer to Image 1.2.1, 1.2.2, 1.2.3, 1.2.4

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

Remove the 254-7304 Top Transmission Cooler Hose by removing (2) 208-6054 T-bolt Clamps. Refer to Image 1.3.1

Image1.3.1

Assemble the 322-9716 Tube to the top port on the oil cooler with (1) 324-9860 Hose and (4) 8T4984 Clamps. Assemble the other end of the 322-9716 Tube to the back of the oil cooler located on the engine with (1) 324-9860 Hose and (4) 8T4984 Clamps.
Note: The torque for the 8T4984 Clamp is 12 +/- 1 NM (5/16" HEX).
Refer to Image 1.4.1, 1.4.2 and 1.4.3.

Refill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".