PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW STEERING CYLINDER RELIEF VALVES AND REWORKING PARKING BRAKES ON CERTAIN 725, 730 EJECTOR, 730, 735, 740 EJECTOR, AND 740 ARTICULATED TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW STEERING CYLINDER RELIEF VALVES AND REWORKING PARKING BRAKES ON CERTAIN 725, 730 EJECTOR, 730, 735, 740 EJECTOR, AND 740 ARTICULATED TRUCKS

Usage:

REBE4404-01

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16Jan2009

(Revised 25Mar2009)

U-21

A-19

D-18

O-17

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW STEERING CYLINDER RELIEF VALVES AND REWORKING PARKING BRAKES ON CERTAIN 725, 730 EJECTOR, 730, 735, 740 EJECTOR, AND 740 ARTICULATED TRUCKS
4267 4322 4263		PI10734

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10734" 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 "PI10734" 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:	This Revised Service Letter replaces the 16Jan2009 Service Letter. Changes have been made to the Group 2 Rework Procedure, Group 2 Service Claim Allowances, and to the inspection Process.

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PROBLEM

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The parking brake yoke and parking brake canister retaining nuts may come loose resulting in failure of the parking brake assembly on certain 725, 730 Ejector, 730, 735, 740 Ejector, and 740 Articulated Trucks. The steering external relief valves need to be replaced on certain 725, 730 and 730 Ejector Articulated Trucks. If the relief valve does not operate properly, the 138-1462 Front Frame Group may crack at the steering cylinder mountings. If the steering cylinder mountings crack, the steering may not respond as expected. Failure to have the applicable improvements made could result in a potential personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
725	B1L02128-02166, 2168, 2170-2171, 2173, 2175, 2177-2178, 2180, 2182-2183, 2185, 2187-2189, 2191-2201, 2203, 2205-2209, 2214-2215, 2218-2225
730	B1M02343-02350, 2352-2399, 2401-2407, 2409-2416, 2419-2420, 2424-2425, 2428-2447, 2449, 2451-2456, 2458-2474, 2476, 2482, 2488
730EJ	B1W00350-00353
735	AWR00207-00880 B1N00131-01214, 1216, 1218-1220, 1223-1238, 1240-1256, 1263-1268
740	AXM00219-02154 B1P00141-04669, 4673-4764, 4769-4784, 4789-4790, 4794-4796, 4804-4805, 4807
740 OEM	DTX00102-00121
740EJ	AZZ00262-00390 B1R00151-00481
9C BULLDOZER	05A13573
CIPI	0EM01782
TH55	KCH22009

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*****Group 2*****
725	AFX00074-01019, 1021-1648 B1L00111-02076, 2078-2083, 2085-2127
730	AGF00175-01561 B1M00121-02342
730EJ	B1W00161-00346, 348-349
9C BULLDOZER	05A13211, 13232-13233

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
This Group does not have any parts.
*****Group 2*****
2	3293030	VALVE GP-RELIEF
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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For GROUP 1 and 2: The parking brake yoke needs to be removed, thread lock applied to the yoke threads, and re-tightened. The torque on the two canister nuts needs to be checked and tighten if found loose. Adjust the parking brake to insure the correct running clearance. Refer to the attached Rework Procedure.

Group 2: The steering cylinder external relief valves need to be replaced on certain 725, 730 Ejector and 730 Articulated Trucks. 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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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 2.0-hour job for Group 1
2 hours to perform the Group 1 rework procedure.

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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 3.0-hour job for Group 2
2 hours to perform the Group 1 rework procedure and 1 hour to perform the group 2 rework procedure. 15 additional labor hours may be claimed if Special instruction REHS2595 must be performed if cracking is discovered during mounting bracket inspection described in group number 2, step 5.

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW STEERING CYLINDER RELIEF VALVES AND REWORKING PARKING BRAKES

MODELS INVOLVED - 725, 730 EJECTOR, 730, 735, 740 EJECTOR, AND 740 ARTICULATED TRUCKS

Dear Caterpillar Product Owner:

The external steering cylinder relief valve needs to be replaced, the parking brake yoke needs to be reworked, and the torque on the parking brake canister nuts needs to be inspected. The existing external steering cylinder relief valve can fail resulting in the lose of steering. The parking brake yoke or canister can fail causing loss of the parking brake function. Failure to have the applicable improvements made could result in potential personal injury or death. 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 16Jan2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 16Jan2009 Service Letter

Rework Procedure

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Group Number 1

Parking Brake Canister Nut Torque Check

1. Park the machine on level ground.

2. Install the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

3. Place the transmission shift lever in NEUTRAL, raise dump body and install Safety strut, engage the parking brake, stop the engine, and turn the battery disconnect switch to the "Off" position.

4. Block the wheels.

5. Discharge the park brake system pressure.

6. Clean the parking brake of all loose material and dirt.

7. Set the torque wrench to 40 Nm (30 ft-lbs) and check the two nuts shown. If the nuts do not move, then the torque is correct. If the nuts move while carrying out this check, move onto the next step.

8. Loosen the nuts one at a time. Set the torque wrench to 47.5 +/- 7 Nm (35 +/- 5 ft-lbs) and tighten the bolts.

Image1.1.1

Parking Brake Yoke Rework

Image1.2.1

9. Manually disengage the parking brake. Rotate Actuator Shaft (2) clockwise (as indicated by the arrow). Rotate the actuator shaft until Pin (5) is loose.

NOTE: If the actuator shaft is loose and not making contact with the yoke, the yoke needs to be replaced.

Image1.3.1

Image1.3.2

10. Remove Cotter Pin (4) that secures Pin (5) between Yoke (6) and Lever (7).
11. Remove Pin (5).

Image1.4.1

12. Push Lever (7) fully forward (as indicated by the arrow) in order to remove Yoke (6) fully from Actuator Shaft (2).

Image1.5.1

13. Apply 4C-4030 or 9S-3263 Thread Lock to the yoke threads in the area shown by item (8) in Image 1.5.1. Thread lock should be applied on the yoke treads that will be engaged by the actuator rod. Install the parking brake yoke into Actuator Shaft (2) on Parking Brake Actuator (3).

14. Apply suitable anti-seize compound to Pin (5) before installing the pin between Lever (7) and Yoke (6).

15. Install Cotter Pin (4) into Pin (5) in order to secure Yoke (6) and Lever (7) together.

Image1.6.1

16. Turn Actuator Shaft (2) counterclockwise (as indicated by the arrow) in order to engage the parking brake. Tighten to a torque of 21 Nm (15 ft-lbs).

17. Adjust the running clearance on the parking brake by following the procedures in Testing and Adjusting 735, 740 and 740 Ejector Articulated Trucks Braking System, RENR5129, Parking Brake - Adjust and Operation and Maintenance Manual 725 and 730 Articulated Trucks, SEBU7814, Adjusting the Parking Brake.

NOTE: The parking brake should never be adjusted by loosening the parking brake yoke to actuator rod. This joint must remain tight.

18. Start the engine.

19. Check the parking brake is engage.

20. Raise the body into the RAISED position and remove the safety strut. Also ensure that the body prop is lowered.

21. Lower the body.

22. Stop the engine.

23. Remove any blocks from the wheels.

24. Remove the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

Group Number 2

Machine Preparation

1. Park the machine on level ground.

2. Install the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".

3. Place the transmission shift lever in NEUTRAL, engage the parking brake, stop the engine, and turn the battery disconnect switch to the "Off" position.

4. Block the wheels.

5. Inspect the mounting bracket on the frame for signs of cracking. If the bracket is cracked, it should be replaced using the procedure documented in Special Instruction, REHS2595.

6. Remove the external relief valve from the mounting port on the steering cylinder manifold ? see illustration below. Take the appropriate safety precautions when removing the valve as the cylinder may contain fluid under pressure.

Image2.2.1

7. Install a new 329-3030 Valve Group-Relief in place of the original valve. Tighten the new valve to a torque of 28 +/- 5 Nm (21 +/- 4 ft-lbs). Do not over-tighten the valve.

8. Repeat Steps 5 ? 7 of this procedure for the opposite side steering cylinder and mounting bracket.

9. Start the engine and check the operation of the steering system by turning the machine fully in both right and left-hand directions several times.

10. Check for oil leaks. If leaks are present, repair them and re-test the steering operation before returning the machine to normal operation.