PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN ORIFICE IN THE TORQUE CONVERTER LOCKUP CLUTCH SUPPLY LINE ON CERTAIN 777F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN ORIFICE IN THE TORQUE CONVERTER LOCKUP CLUTCH SUPPLY LINE ON CERTAIN 777F OFF-HIGHWAY TRUCKS

Usage:

REBE5569-00

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10Nov2009

U-380

A-311

D-340

O-341

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN ORIFICE IN THE TORQUE CONVERTER LOCKUP CLUTCH SUPPLY LINE ON CERTAIN 777F OFF-HIGHWAY TRUCKS
3103 3067		PI31699

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31699" 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 "PI31699" 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
31May2010	30Nov2010

PROBLEM

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The torque converter lockup clutch supply pressure spikes up to 1000 psi on certain 777F Off-Highway Trucks. The spikes can cause the existing torque converter lockup clutch supply filter base to crack and leak oil. An orifice needs to be installed in the torque converter lockup clutch supply line to prevent the spikes.

AFFECTED PRODUCT

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Model	Identification Number
777F	JRP00277-02108
777F OEM	JXP00100-00136 WTK00105-00117

PARTS NEEDED

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Qty	Part Number	Description
1	3D2824	SEAL-O-RING
1	6V9746	SEAL-O-RING-ORFS
1	1757963	CONNECTOR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 43% 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 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 1.5-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.

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN ORIFICE IN THE TORQUE CONVERTER LOCKUP CLUTCH SUPPLY LINE ON CERTAIN 777F OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 777F Off-Highway Trucks

Dear Caterpillar Product Owner:

The torque converter lockup clutch supply pressure spikes up to 1000 psi on the products listed below. The spikes can cause the existing torque converter lockup clutch supply filter base to crack and leak oil. An orifice needs to be installed in the torque converter lockup clutch supply line to prevent the spikes. 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 10Nov2009 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 10Nov2009 Service Letter

Rework Procedure

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1. Locate and remove the 148-8327 Connector Assembly from the supply line and converter housing. Refer to Image1.1.1 below.

Image1.1.1

2. Install a 3D2824 O-ring Seal to larger end of 175-7963 Orifice Adapter and install a 6V9746 O-ring Seal to smaller end of 175-7963 Orifice Adapter. Refer to Image1.2.1 below.

Image1.2.1

3. Install the orifice adapter assembly in the supply line and converter housing.

4. Follow Testing and Adjusting RENR8342 "Transmission Clutch ? Calibrate" to reset lock-up clutch pressure to 2138 kpa (310 psi).