PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 270-4225 BRAKE COOLER GROUP ON CERTAIN 770 AND 772 OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 270-4225 BRAKE COOLER GROUP ON CERTAIN 770 AND 772 OFF-HIGHWAY TRUCKS

Usage:

REBE4417-00

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19Dec2008

U-656

A-544

D-558

O-598

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 270-4225 BRAKE COOLER GROUP ON CERTAIN 770 AND 772 OFF-HIGHWAY TRUCKS
1365		PI31605

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31605" 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 "PI31605" 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:

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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COMPLETION DATE	TERMINATION DATE
30Jun2009	31Dec2009

PROBLEM

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The 270-4225 Brake Cooler Group needs to be reworked on certain 770 and 772 Off-Highway Trucks. The existing 276-1859 and 276-1860 Hose Assemblies can fail causing loss of engine coolant.

AFFECTED PRODUCT

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Model	Identification Number
770	BZZ00069-00206, 208-439
770 OEM	M7W00103
772	RLB00271-00416, 419-514
772 OEM	J2M00100-00101

PARTS NEEDED

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Qty	Part Number	Description
2	6V1581	CLIP-2 PIECE
2	6V1582	CLIP-2 PIECE
4	7X7729	WASHER
2	8T4133	NUT
2	8T4196	BOLT
16	8T4984	CLAMP-BAND
1	2598359	PLATE
1	3234709	TUBE
1	3234710	TUBE
1	3234711	HOSE
2	3249860	HOSE
1	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 276-1859 Hoses and 276-1860 Hose from dealer parts stock.

****Affected Product****

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Refer to the Service Manual and 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 3.0-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 REWORKING THE 270-4225 BRAKE COOLER GROUP ON CERTAIN 770 AND 772 OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 770 and 772 Off-Highway Trucks

Dear Caterpillar Product Owner:

The 270-4225 Brake Cooler Group needs to be reworked on the products listed below. The existing 276-1859 and 276-1860 Hose Assemblies can fail causing loss of engine coolant. 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 19Dec2008 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 19Dec2008 Service Letter

Rework Procedure

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1. Drain the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
2. Remove eight 208-6054 T-Bolt Clamps (A). Refer to Illustration 1.1.1

Image1.1.1

3. Remove three 8T4136 Bolts (B), two 8T4137 Bolts (C), and five 8T4121 Washers (D). Remove four 122-3608 Clips (E) and one 299-2091 Bracket As (F). Refer to Illustration 1.2.1

Image1.2.1

4. Remove the 276-1859 Hose As (G) and 276-1860 Hose As (H). Refer to Illustration 1.3.1

Image1.3.1

5. Loosely fit the 323-4711 Hose As. (I), 324-9860 Hose As. (J), and the eight 8T4894 Clamps to 323-4710 Tube As. (L). Refer to Illustration 1.4.1

Image1.4.1

6. Loosely fit the 326-2945 Hose As. (M), 324-9860 Hose As. (N), and the eight 8T4894 Clamps (K) to the 323-4709 Tube As. (P). Illustration 1.5.1

Image1.5.1

7. Assemble the lower tube assembly from Step 5 in the machine as shown in Illustration 1.6.1. Do not tighten clamps until Step 10.

8. Assemble the Upper tube assembly from Step 6 in the machine as shown in Illustration 1.6.1. Do not tighten clamps until Step 10.

Image1.6.1

9. Assemble two 6V1581 Clips (Q), two 6V1582 Clips (R), and one 259-8359 Plate (S) with two 8T4196 Bolts (T), four 7X7729 Washers (U), and two 8T4133 Nuts (V) as shown in Illustration 1.7.1

Image1.7.1

10. Tighten all hose clamps to a torque of 11 Nm.
11. Refill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".