PRODUCT SUPPORT PROGRAM FOR REPLACING THE RETARDER ELECTRO-HYDRAULIC VALVE GROUP ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RETARDER ELECTRO-HYDRAULIC VALVE GROUP ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS

Usage:

REBE5581-00

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04Feb2010

U-47

A-38

D-41

O-44

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Before/After Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RETARDER ELECTRO-HYDRAULIC VALVE GROUP ON CERTAIN 797 AND 797B OFF-HIGHWAY TRUCKS
4282 4265		PS43033

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43033" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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, "7755" as the Group Number, "56" as the Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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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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TERMINATION DATE

28Feb2011

PROBLEM

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The existing 155-5989 or 335-8811 Valve Group can fail on certain 797 and 797B Off-highway Trucks. If the existing valve group fails, excessive pressure may be exerted on the service brake packs which can subsequently lead to seal extrusion and oil leakage.

AFFECTED PRODUCT

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Model	Identification Number
797	5YW00193-00277
797B	JSM00123-00488

PARTS NEEDED

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Qty	Part Number	Description
1	3521111	VALVE GP-SOL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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 155-5989 and 335-8811 Valve Groups from dealer parts stock. Rework all 2796515/">279-6515 and 335-8812 Mounting and Valve Groups in order to remove either the 155-5989 or 335-8811 Valve Group and replace with a 352-1111 Valve Group. Insure the 352-1111 Valve Group is torqued to the proper value during installation. Reference RENR2580 for final installation torque valves.

When reworking the 2796515 or 335-8812 Mounting & Valve Groups, a 0.5 hour of labor will be allowed per Mounting & Valve Group that is reworked.

****Affected Product****

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NOTE: To minimize the chance of contaminating the hydraulic system. It is very important to thoroughly clean the area as described in Step 1 below.

1. Locate the retarder control valve on the machine. Thoroughly remove any dirt or other material from the existing valve group and valve mounting group (valve manifold).

2. Remove the existing 155-5989 Valve Group or 335-8811 Valve Group from the Valve & Mounting Group. Ensure no debris enters the valve cavity when the valve group is removed.

3. Install the new 352-1111 Valve Group in the Valve & Mounting Group. Refer to RENR2580 for final installation torque values.

4. Purge entrapped air from brake lines. Refer to RENR2581 (Brake System Air - Purge). Pay special attention to Steps 9 through 13 of the purge procedure.

5. Using the configuration screen in CAT Electronic Technician, verify that the ARC Hi Calibrate parameter (1) is equal to 87.4% (2). Refer to Image 1.

6. Perform the Service Brake and Retarder System Pressure Test in order to verify that the retarder system pressure is correct. Reference RENR2581.

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Image1

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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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%
0-40000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%