PRODUCT SUPPORT PROGRAM FOR INSTALLING THE 419-3252 LINES-GP HOIST ON CERTAIN 777F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING THE 419-3252 LINES-GP HOIST ON CERTAIN 777F OFF-HIGHWAY TRUCKS

Usage:

REBE8523-01

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23Jul2012

(Revised 17Jan2013)

T030
T050
T210

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING THE 419-3252 LINES-GP HOIST ON CERTAIN 777F OFF-HIGHWAY TRUCKS
5264 5057		PS43656

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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 "PS43656" 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:

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:	This Revised Service Letter replaces the 23Jul2012 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Jul2014

PROBLEM

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The existing 266-7223 Hoist Lines-Gp can fail on certain 777F Off-Highway Trucks. If the existing 266-7223 Hoist Lines-Gp fails it can cause the tube assembly to crack over time.

AFFECTED PRODUCT

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Model	Identification Number
777F	JRP01708-01709, 1723-1724, 1897-1898, 1912, 2219-2221, 2224, 2226-2230, 2436, 2449, 2458, 2462-2466, 2471-2472, 3113, 3115, 3117, 3132, 3134, 3136-3138, 3140-3142, 3144-3146, 3161, 3163, 3324

PARTS NEEDED

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Qty	Part Number	Description
8	0S1588	BOLT
8	1P4577	FLANGE-HALF
8	1P4578	FLANGE-HALF
8	1P4579	FLANGE-HALF
6	4J0520	SEAL-O-RING
4	4J0522	SEAL-O-RING
4	4J0524	SEAL-O-RING
8	5M2894	WASHER-HARD
8	5P2566	BOLT
2	5P7468	CLIP-HALF SLOT
2	5P7469	CLIP-HALF TANG
3	5P7470	CLIP-HALF SLOT
3	5P7471	CLIP-HALF TANG
2	5P7703	GROMMET
1	5P8182	GROMMET
2	5P8444	GROMMET
2	6V0852	CAP-DUST
1	6V1572	CLIP-HALF SLOT
1	6V1573	CLIP-HALF TAB
1	6V1574	GROMMET
2	6V3965	ADAPTER-STR
8	7X0288	BOLT
2	7X7729	WASHER-HARD
16	8T4121	WASHER-HARD
1	8T4133	NUT
1	8T4182	BOLT-HEX HEAD
2	8T4192	BOLT-HEX HEAD
16	8T4196	BOLT-HEX HEAD
22	8T4223	WASHER-HARD
8	8T4896	WASHER-HARD
4	8T4956	BOLT-HEX HEAD
8	8T5041	BOLT-HEX HEAD
2	8X7224	PLATE-ORIFICE
4	9R9254	BOSS
2	2147568	SEAL-O-RING-STOR
1	2206113	BLOCK
1	3592782	PLATE
1	3592783	PLATE
2	3836765	MANIFOLD
2	3844579	HOSE AS
2	3844580	HOSE AS
1	3844581	HOSE AS
1	3844586	BRACKET
1	3974879	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 6.0-hour job
When required, 2 additional hours of labor will be allowed for prep time. Travel time/mileage will be allowed per the warranty bulletin.

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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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Step 1
Reference Disassembly and Assembly, RENR8311, "Hydraulic System Pressure - Release"
Remove all parts related to 266-7223 Lines GP ? Hoist Diagram and 266-7223 parts list.

Step 2
Remove bosses from Drop Tube marked in red shown in image below.

Image1.2.1

Step 3
Remove block from Cross Tube marked in red shown in image below.

Image1.3.1

Image1.3.2

Step 4
Locate and weld 220-6113 Mounting Block to the Cross Tube.
Reference measurements in image below.

Image1.4.1

Step 5
Locate and weld the four 9R-9254 Bosses to the Drop Tube.
Reference measurements in image below.

Image1.5.1

Step 6
Locate and weld 359-2782 and 359-2783 Plates to the Drop Tube.
Reference measurements in image below.

Image1.6.1

Image1.6.2

Image1.6.3

Step 7
Install 164-5567 Coupler Assembly and 6V-0852 Dust Cab to 383-6765 Manifold

Image1.7.1

Step 8
Install 4J-0524 O-Rings to 384-4581 and 397-4879 Hose Assemblies. Install 384-4581 Hose Assembly and 397-4879 Hose Assembly to Hoist Control Valve using 1P-4579 Flanges, 5P-2566 Bolts, and 8T-4223 Washers.
Reference image below.

Image1.8.1

Step 9
Install 4J-0524 O-Rings to 384-4581 and 397-4879 Hose Assemblies.
Install 384-4581 Hose Assembly and 397-4879 Hose Assembly to 383-6765 Manifolds using 1P-4579 Flanges, 8T-5041 Bolts, and 8T-4223 Washers.
Reference image below.

NOTE: 8T-5041 Bolts will go through 383-6765 Manifold and secure to the 359-2783 Plate.

Image1.9.1

Image1.9.2

Step 10
Install 384-4586 Bracket to the 220-6113 Block on the Cross Tube using the 8T-4192 Bolts and 8T-4223 Washers. Install 6V-1574 Grommet, 6V-1573 Clip, and 6V-1572 Clip to 386-4581 Hose Assembly. Install 5P-8182 Grommet, 5P-7470 Clip, and 5P-7471 Clip to 397-4879 Hose Assembly. With Clips in place, secure them to 384-4586 Bracket using 8T-4182 Bolt, 8T-4133 Nut, and 7X-7729 Washers.
Reference image below.

NOTE: Notice orientation of clips shown in image.

Image1.10.1

Step 11
Install 4J-0522 O-Ring to 384-4579 Hose Assemblies and 384-4580 Hose Assemblies. Install 384-4579 Hose Assemblies and 384-4580 Hose Assemblies to the 383-6765 Manifolds using 1P-4578 Flanges, 8T-4196 Bolts, and 8T-4121 Washers.
Reference image below.

Image1.11.1

Step 12
Install 4J-0520 O-Rings to 384-4579 and 384-4580 Hose Assemblies. Attach 384-4579 Hose Assemblies to the Hoist Cylinders using 1P-4577 Flanges, 0S-1588 Bolts, and 5M-2894 Washers. Attach 384-4580 Hose Assemblies to Hoist Cylinders using 1P-4577 Flanges, 7X-0288 Bolts, 8T-4896 Washers, and 8X-7224 Orifice Plates.
Reference image below.

Image1.12.1

Step 13
Install 5P-8444 Grommet, 5P-7468 Clip, 5P-7469 Clip, 8T-4956 Bolt, and 8T-4223 Washer to 384-4580 Hose Assemblies, and attach to 9R-9254 Bosses. Install 5P-7703 Grommet, 5P-7471 Clip, 5P-7470 Clip, 8T-4956 Bolt, and 8T-4223 Washer to 384-4579 Hose Assemblies, and attach to 9R-9254 Bosses.
Reference image below.

NOTE: Make certain hose assemblies do not touch or rub, and are secure in clips.