PRODUCT SUPPORT PROGRAM FOR INSTALLING A 352-6554 VALVE GROUP ON CERTAIN 777F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A 352-6554 VALVE GROUP ON CERTAIN 777F OFF-HIGHWAY TRUCKS

Usage:

REBE8536-00

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11Jul2012

K030
K031

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING A 3526554/">352-6554 VALVE GROUP ON CERTAIN 777F OFF-HIGHWAY TRUCKS
7755 4257 4261 5117		PS90117

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NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. The service reps Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90117" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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

31Jul2013

PROBLEM

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The existing service and parking brake group can exhibit brake dragging on certain 777F Off-Highway Trucks. If continuous brake dragging occurs it can lead to high brake oil temperatures and logged events.

AFFECTED PRODUCT

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Model	Identification Number
777F	JRP00750, 1533, 1563-1564, 1785, 1807, 1811, 1832, 1913-1914, 1919, 1921-1922, 1991, 1999-2000, 2009, 2019, 2047
777F OEM	JXP00219-00220, 232

PARTS NEEDED

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Qty	Part Number	Description
2	3D2824	SEAL-O-RING
4	3K0360	SEAL-O-RING
13	6V9746	SEAL-O-RING-ORFS
2	6V9839	ADAPTER-TEE
1	6V9853	ADAPTER-ELBOW
2	6V9874	ADAPTER-STR
2	7I1036	ADAPTER-STR
2	7I8310	ADAPTER-STR
1	2617957	ADAPTER
2	2635846	BODY
2	3526554	VALVE GP-D RLF-B
2	3881571	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 3.0-hour job

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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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1. Disconnect hose assembly (A) and hose assembly (B) from slack adjuster (C). Disconnect hose assembly (D) from adapter (E). Remove adapter (E) from slack adjuster (C). The adapter will not be reused. Refer to Image1.1.1.

Image1.1.1

2. Assemble 7I-8310 Adapter (1) to slack adjuster (C) with 3D-2824 O-Ring Seal (2). Tighten 7I-8310 Adapter (1) to a torque of 110 +/- 17 N.m (81 +/- 13 lb ft). Assemble 261-7957 Adapter (3) to 7I-8310 Adapter (1) with 6V-9746 O-Ring Seal (4). Tighten 261-7957 Adapter (3) to a torque of 160 +/- 24 N.m (118 +/- 18 lb ft). Refer to Image1.2.1.

Image1.2.1

3. Assemble one 6V-9839 Adapter (5) to each side of the slack adjuster (C) with one 6V-9746 O-Ring Seal (4). Tighten each 6V-9839 Adapter (5) to a torque of 160 +/- 24 N.m (118 +/- 18 lb ft). Assemble one 7I-1036 Adapter (6) to each of the 6V-9839 Adapter (5) with one 6V-9746 O-Ring Seal (4). Tighten each 7I-1036 Adapter (6) to a torque of 160 +/- 24 N.m (118 +/- 18 lb ft). Refer to Image1.3.1.

Image1.3.1

4. Assemble one 263-5846 Body (7) to each of the 7I-1036 Adapter (6) with one 3K-0360 O-Ring Seal (8). Tighten each 263-5846 Body (7) to a torque of 110 +/- 17 N.m (81 +/- 13 lb ft). Assemble one 3526554/">352-6554 Valve Group (9) to each of the 263-5846 Body (7). Tighten each 3526554/">352-6554 Valve Group (8) to a torque of 24 +/- 3 N.m (18 +/- 2 lb ft). Refer to Image1.4.1.

Image1.4.1

5. Assemble one 6V-9874 Adapter (10) to each of the 263-5846 Body (7) with one 3K-0360 O-Ring Seal (8). Refer to Image1.5.1. Tighten each 6V-9874 Adapter (10) to a torque of 110 +/- 17 N.m (81 +/- 13 lb ft). Assemble one 388-1571 Hose As. (11) to each of the 6V-9874 Adapter (10) with one 6V-9746 O-Ring Seal (4). Refer to Image1.5.2. Assemble opposite end of each of the 388-1571 Hose Assembly (11) to 261-7957 Adapter (3) with one 6V-9746 O-Ring Seal (4). Refer to Image1.5.3. Tighten the swivel nut on both ends of each 388-1571 Hose Assembly (11) to a torque of 160 +/- 24 N.m (118 +/- 18 lb ft).

Image1.5.1

Image1.5.2

Image1.5.3

6. Assemble 6V-9853 Adapter (12) to 261-7957 Adapter (3) with one 6V-9746 O-Ring Seal (4). Refer to Image1.6.1. Tighten 6V-9853 Adapter (12) to a torque of 160 +/- 24 N.m (118 +/- 18 lb ft). Connect hose assembly (A) and hose assembly (B) to each of the 6V-9839 Adapter (5) with one 6V-9746 O-Ring Seal (4). Refer to Image1.6.2. Tighten the swivel nut on hose assembly (A) and hose assembly (B) to a torque of 160 +/- 24 N.m (118 +/- 18 lb ft). Connect hose assembly (D) in Step 1 to 6V-9853 Adapter (12) with one 6V-9746 O-Ring Seal (4). Refer to Image1.6.1. Tighten the swivel nut on hose assembly (D) to a torque of 160 +/- 24 N.m (118 +/- 18 lb ft).