PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR BRAKE COOLING TUBE ASSEMBLY ON CERTAIN 793D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR BRAKE COOLING TUBE ASSEMBLY ON CERTAIN 793D OFF-HIGHWAY TRUCKS

Usage:

REBE6173-01

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28Sep2010

(Revised 14Dec2010)

U-394

A-311

D-340

O-343

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After Failure Only Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR BRAKE COOLING TUBE ASSEMBLY ON CERTAIN 793D OFF-HIGHWAY TRUCKS
5056		PS51902

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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 "PS51902" 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:

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.

NOTE:	This Revised Service Letter replaces the 28Sep2010 Service Letter. Changes have been made to the Service Claim Allowances to allow for part hours.

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TERMINATION DATE

30Sep2012

PROBLEM

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The existing rear brake cooling tube assembly can fail on certain 793D Off-Highway Trucks. If the existing tube assembly fails it can cause increased temperature to the rear brakes which can cause premature brake wear or failure.

AFFECTED PRODUCT

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Model	Identification Number
793D	FDB00121-01335

PARTS NEEDED

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Qty	Part Number	Description
2	1H0474	SEAL-O-RING
2	5F3092	SEAL-O-RING
7	6V7611	BOLT-LOCKING
7	1984767	WASHER-HARD
1	2042635	GASKET
1	2474808	TUBE AS.
1	3526043	TUBE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 247-4809 Tube Assemblies from dealer parts stock.

****Affected Product****

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Replace the existing 247-4809 Tube Assembly with a new 352-6043 Tube Assembly and update the bolts and washers used on the 251-9616 Bracket Assembly.

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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%
0-6000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 8.0-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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****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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Rework Procedure

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Prior to performing any of the outlined work, reference: Disassembly and Assembly Manual - RENR8332 - 793D Off-Highway Truck Machine Systems.

Replace the current 247-4809 Tube Assembly with a new 352-6043 Tube Assembly (Image 1.1.1). A high performance lubricant is recommended to ease assembly of the tube into the tank wall.

The 247-4808 Tube Assembly should be inspected. If the tube assembly is cracked or utilizes a fillet weld to attach the flange to the tube, the tube should be replaced with a new 247-4808 Tube Assembly. The current 247-4808 Tube Assembly uses a brazed connection to attach the flange to the tube. The brazed connection improves the strength of the tube assembly.

Image1.1.1

The former 247-4809 Tube Assembly used a formed double upset end to retain the seal. The new 352-6043 Tube Assembly uses a thick wall machined end with a brazed connection to the tube assembly (Image 1.2.1).

Image1.2.1

To minimize stresses on the tube and on the tank wall, the bolts that attach to the 251-9616 Plate Assembly should also be replaced.

- Replace (4) 7D-1649 Washers and (4) 6V-8097 Bolts that mount the bracket to the bottom of the tank with (4) 198-4767 Washers and (4) 6V-7611 Bolts (Image 1.3.1 and 1.3.2).

- Replace (3) 7D-1649 Washers and (3) 6V-8097 Bolts that mount the motor to the bracket with (3) 198-4767 Washers and (3) 6V-7611 Bolts. These bolts should be replaced and torqued to specification one bolt at a time to maintain pump alignment (Image 1.3.1).