PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CHECK AND RELIEF VALVES IN THE STEERING VALVE GROUP ON CERTAIN 789C AND 789D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CHECK AND RELIEF VALVES IN THE STEERING VALVE GROUP ON CERTAIN 789C AND 789D OFF-HIGHWAY TRUCKS

Usage:

REBE8512-00

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22Aug2012

U-443

A-354

D-379

O-408

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Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CHECK AND RELIEF VALVES IN THE STEERING VALVE GROUP ON CERTAIN 789C AND 789D OFF-HIGHWAY TRUCKS
4307		PI10902

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10902" 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 "PI10902" 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:

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, "7751" as the Group Number, "56" as the Description Code.

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PROBLEM

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One or both of the inner cartridge of the 9T-4010 Check and Relief Valve Group may have been under tightened during assembly on certain 789C and 789D Off-Highway Trucks. If this condition exist in the truck, steering tends to degrade gradually as one or both of the valves continues to loosen. As the truck is steered, the machine may tend to drift either right or left depending on which 9T-4010 Check and Relief Valve Group is failing. If not addressed, the steering may continue to degrade until steering in one or both directions is lost completely and may, in conjunction with other factors and circumstances, create a risk of personal injury or death. This failure occurs at lower machine hours. If the machine has over 2,000 hours without exhibiting any of these issues, it should not need to be checked.

AFFECTED PRODUCT

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Model	Identification Number
789C	2BW01816-02128
789D	SHH00288-00306 SPD00166-00238, 240, 242, 244-252, 254, 256-260

PARTS NEEDED

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Qty	Part Number	Description
1	9T4010	VALVE GP-CHECK-B
1	3624667	KIT-SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 9T-4010 Check and Relief Valve Group with date code 43/10 or 20/11. Remove all 9T-1317 Steering Valve Groups from dealer parts stock and rework in accordance to the following instructions.

1. Remove the 141-8245 Cover and 141-8247 Cover from each end of the 9T-1317 Steering Valve Group.

2. Remove the plate and O-rings from each end of the valve, as necessary.

3. As indicated in SENR1534, Disassembly and Assembly, "Steering Control Valve - Disassemble", use a screwdriver in order to remove the 9T-4010 Check and Relief Valve Group (B) from each end of 9T-1317 Steering Control Valve (A). Refer to Image1. Gently pry until the valve dislodges from the O-ring that is retaining it.

4. Note the date code on each 9T-4010 Check and Relief Valve Group. If a date code of 43/10 or 20/11 is found, replace the corresponding valve with a new valve. If the date code is not 43/10 or 20/11, or if no date code is present, check the lock nut for the required tightening specifiation. Refer to Image2.

5. Use either a center punch or appropriately sized external hexagonal socket in order to support and retain the end of the 9T-4010 Check and Relief Valve Group (B). Refer to Image3 and Image4. Keep the 9T-4010 Check and Relief Valve Group from turning. Using a torque wrench, tighten the 13mm lock nut to a specified torque of 20.0 +/- 1.0 N.m (177 +/- 8 lb-in). If the jam nut moves, replace the valve as the internal O-ring may have eroded.

6. Carefully reassemble the 9T-1317 Steering Control Valve according to SENR1534, Disassembly and Assembly, "Steering and Control Valve - Assemble". After starting the truck, drive and maneuver the truck to verify proper steering operation.

7. Record both codes on each of 9T-4010 Check and Relief Valve Group and the serial number of the 9T-1317 Steering Control Valve in the claim story.

****Affected Product****

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1. Remove the 9T-1317 Steering Control Valve from the machine. Refer to SENR1534, Disassembly and Assembly, "Steering Control Valve - Remove".

2. Clean and protect the 9T-1317 Steering Control Valve as necessary in order to control contamination. Refer to Image1.

3. Remove the 141-8245 Cover and 141-8247 Cover from each end of the 9T-1317 Steering Valve Group.

4. Remove the plate and O-rings from each end of the valve, as necessary.

5. As indicated in SENR1534, Disassembly and Assembly, "Steering Control Valve - Disassemble", use a screwdriver in order to remove the 9T-4010 Check and Relief Valve Group (B) from each end of 9T-1317 Steering Control Valve (A). Refer to Image1. Gently pry until the valve dislodges from the O-ring that is retaining it.

6. Note the date code on each 9T-4010 Check and Relief Valve Group. If a date code of 43/10 or 20/11 is found, replace the corresponding valve with a new valve. If the date code is not 43/10 or 20/11, or if no date code is present, check the lock nut for the required tightening specification. Refer to Image2.

7. Use either a center punch or appropriately sized external hexagonal socket in order to support and retain the end of the 9T-4010 Check and Relief Valve Group (A). Refer to Image3 and Image4. Keep the 9T-4010 Check and Relief Valve Group from turning. Using a torque wrench, tighten the 13mm lock nut to a specified torque of 20.0 +/- 1.0 N.m (177 +/- 8 lb-in). If the jam nut moves, replace the valve as the internal O-ring may have eroded.

8. Carefully reassemble and install the 9T-1317 Steering Control Valve on to the machine according to SENR1534, Disassembly and Assembly, "Steering and Control Valve - Assemble" and "Steering and Control Valve - Install". After starting the truck, drive and maneuver the truck to verify proper steering operation.

9. Record both codes on each of 9T-4010 Check and Relief Valve Group and the serial number of the 9T-1317 Steering Control Valve in the claim story.

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Image1

Image2

Image3

Image4

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 5.0-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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For NACD

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Caterpillar Inc.

Attn: Supplier Recovery

Service Claims Room

8201 N. University

Peoria, IL 61615

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CHECK AND RELIEF VALVE IN THE STEERING VALVE GROUP ON CERTAIN OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 789C and 789D Off-Highway Trucks

Dear Cat Product Owner:

One or both of the inner cartridge of the 9T-4010 Check and Relief Valve Group may have been under tightened during assembly on certain 789C and 789D Off-Highway Trucks. If not addressed, the steering may continue to degrade until steering in one or both directions is lost completely and may, in conjunction with other factors and circumstances, create a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat 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 22Aug2012 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 22Aug2012 Service Letter