PRODUCT SUPPORT PROGRAM FOR REWORKING AND REPLACING BRAKE SEALS ON CERTAIN R1600G LOAD HAUL DUMP MACHINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING AND REPLACING BRAKE SEALS ON CERTAIN R1600G LOAD HAUL DUMP MACHINES

Usage:

REBE5573-02

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16Dec2009

(Revised 14May2010)

U-435

A-356

D-387

O-391

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING AND REPLACING BRAKE SEALS ON CERTAIN R1600G LOAD HAUL DUMP MACHINES
4251 7555		PS51776

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51776" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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:	NOTE: This Revised Service Letter replaces the 16Dec2009 (Revised 11Jan2010) Service Letter. A Change was made to the termination date. This program is no longer required. The permanent repair is available.

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TERMINATION DATE

31May2010

PROBLEM

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The existing brake seals can fail on certain R1600G Load Haul Dump Machines.
If the existing brake seals fail it can allow brake oil to bypass into the axle compartment.

AFFECTED PRODUCT

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Model	Identification Number
R1600G	9YZ00401-00542

PARTS NEEDED

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Qty	Part Number	Description
2	1U8846	SEALANT-GASKET
2	8R9809	SEAL
2	8T8883	SEAL-O-RING
4	9V3811	BOLT
2	1129723	SEAL
2	1437559	SEAL D-RING
2	2927143	SEAL
2	2955001	RING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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%
0-4000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 13-18 mo	100.0%	75.0%	0.0%	25.0%	0.0%	0.0%
6001-10000 hrs, 19-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 34.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

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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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Table 1

Image1.1.1

Reference: Disassembly and Assembly, KENR6828, "R1600G Load Haul Dump
Power Train".
Reference: Systems Operation Testing and
Adjusting, KENR8502, "Service Brake System
Pressure - Test".
Reference: Systems Operation Testing and
Adjusting, KENR8502, "Pressure Reducing Valve
(Pilot Oil) - Test and Adjust".

Image1.2.1

1. Remove any sharp edges from areas (1) as
illustrated in Image 1.2.1
2. Inspect the new seals for defects prior to
installation.

Test the Service and Parking
Brakes Prior to Installing the Axle

Table 2

Image1.4.1

Image1.4.2

Front Axle Parking Brakes

1. Connect Tooling (A), (B), (D), (E), (L), (M), (N), (O), and (P) to fitting (3).
2. Open the needle valve on Tooling (E).
3. Connect one end of a transparent tube that is 6.4 mm (0.25 inch) in diameter to each air purge valve (1). Place the other end of the tube into a
suitable container for collecting the hydraulic oil.
4. Apply hydraulic pressure. Refer to Table 2 for the correct pressure.
5. Open air purge valves (1). Turn the screw one-half turn to permit oil flow through the tube. As the hydraulic oil flows through the tube, look for air bubbles in the oil. Allow the oil to flow into the container until no air bubbles are visible. Then,
tighten air purge valves (1).
6. Apply hydraulic pressure. Refer to Table 2 for the correct pressure.
7. Close the needle valve on Tooling (E).
8. Monitor the pressure between thirty and sixty minutes. If a pressure drop occurs investigate and resolve the issue. Repeat Step 2 through 8.

Front Axle Service Brakes

1. Connect Tooling (A), (C), (D), (E), (M), (N), (O),
and (P) to fitting (4).
2. Open the needle valve on Tooling (E).
3. Connect one end of a transparent tube that is
6.4 mm (0.25 inch) in diameter to each air purge
valve (2). Place the other end of the tube into a
suitable container for collecting the hydraulic oil.
4. Apply hydraulic pressure. Refer to Table 2 for the
correct pressure.
5. Open air purge valves (2). Turn the screw one-half
turn to permit oil flow through the tube. As the
hydraulic oil flows through the tube, look for air
bubbles in the oil. Allow the oil to flow into the
container until no air bubbles are visible. Then,
tighten air purge valves (2).
6. Apply hydraulic pressure. Refer to Table 2 for the
correct pressure.
7. Close the needle valve on Tooling (E).
8. Monitor the pressure between thirty and sixty
minutes. If a pressure drop occurs investigate and
resolve the issue. Repeat Step 2 through 8.

Image1.8.1

Rear Axle Parking Brakes

1. Connect Tooling (A), (B), (D), (E), (L), (M), (N), (O), and (P) to fitting (8).
2. Open the needle valve on Tooling (E).
3. Connect one end of a transparent tube that is
6.4 mm (0.25 inch) in diameter to each air purge
valve (5). Place the other end of the tube into a
suitable container for collecting the hydraulic oil.
4. Apply hydraulic pressure. Refer to Table 2 for the
correct pressure.
5. Open air purge valves (5). Turn the screw one-half
turn to permit oil flow through the tube. As the
hydraulic oil flows through the tube, look for air
bubbles in the oil. Allow the oil to flow into the
container until no air bubbles are visible. Then,
tighten air purge valves (5).
6. Apply hydraulic pressure. Refer to Table 2 for the
correct pressure.
7. Close the needle valve on Tooling (E).
8. Monitor the pressure between thirty and sixty
minutes. If a pressure drop occurs investigate and
resolve the issue. Repeat Step 2 through 8.

Rear Axle Service Brakes

1. Connect Tooling (A), (C), (D), (E), (M), (N), (O), and (P) to fitting (7).
2. Open the needle valve on Tooling (E).
3. Connect one end of a transparent tube that is
6.4 mm (0.25 inch) in diameter to each air purge
valve (6). Place the other end of the tube into a
suitable container for collecting the hydraulic oil.
4. Apply hydraulic pressure. Refer to Table 2 for the
correct pressure.
5. Open air purge valves (6). Turn the screw one-half
turn to permit oil flow through the tube. As the
hydraulic oil flows through the tube, look for air
bubbles in the oil. Allow the oil to flow into the
container until no air bubbles are visible. Then,
tighten air purge valves (6).
6. Apply hydraulic pressure. Refer to Table 2 for the
correct pressure.
7. Close the needle valve on Tooling (E).
8. Monitor the pressure between thirty and sixty
minutes. If a pressure drop occurs investigate and
resolve the issue. Repeat Step 2 through 8.

Test the Service and Parking
Brakes After Installing the Axle

Image1.13.1

Front Axle Parking Brakes

1. Install Tooling (G), (H), (J), and (L) into parking
brake hose assembly (1).
2. Connect Tooling (B), (D) and (F) to Tooling (J).
3. Purge the air from the braking system.
Reference: Refer to Systems Operation, Testing
and Adjusting, "Braking System Air - Purge" for
the machine that is being serviced.
4. Start the engine and allow the hydraulic oil to
reach normal operating temperature.
5. Release the parking brakes. Observe Tooling (C).
Refer to Table 2 for the correct pressure.
6. If the parking brake release pressure is not correct
test the pressure at the pilot oil pressure reducing
valve. If the pressure is not correct adjust the pilot
oil pressure reducing valve. Refer to Systems
Operation Testing and Adjusting, "Pressure
Reducing Valve (Pilot Oil) - Test and Adjust".

Image1.15.1

Rear Axle Parking Brakes

1. Install Tooling (G), (H), and (J) into parking brake
hose assembly (2).
2. Connect Tooling (B), (D) and (F) to Tooling (J).
3. Purge the air from the braking system.
Reference: Refer to Systems Operation, Testing
and Adjusting, "Braking System Air - Purge" for
the machine that is being serviced.
4. Start the engine and allow the hydraulic oil to
reach normal operating temperature.
5. Release the parking brakes. Observe Tooling (C).
Refer to Table 2 for the correct pressure.
6. If the parking brake release pressure is not correct
test the pressure at the pilot oil pressure reducing
valve. If the pressure is not correct adjust the pilot
oil pressure reducing valve. Refer to Systems
Operation Testing and Adjusting, "Pressure
Reducing Valve (Pilot Oil) - Test and Adjust".

Front Axle and Rear Axle Service Brakes

1. Refer to Systems Operation Testing and Adjusting,
"Service Brake System Pressure - Test".

Residual Pressure Test for the
Service Brake Circuit

1. With the tooling connected start the engine and
allow the hydraulic oil to reach normal operating
temperature.
2. Depress and release the service brake pedal.
Monitor Tooling (C), the residual pressure must
not be greater than 69 kPa (10 psi).
3. If residual pressure is greater than 69 kPa (10 psi).
Refer to Systems Operation Testing and Adjusting,
"Braking System Troubleshooting".