Usage:
27Aug2013 |
Q631
Containment - Before/After (Limited distribution) | PRODUCT SUPPORT PROGRAM FOR REPLACING THE LOW BIAS BRAKE VALVE ON CERTAIN 160M MOTOR GRADERS |
|
4269 | PS90318 |
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. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim. |
NOTE: | When reporting the repair, use "PS90318" 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. |
TERMINATION DATE |
31Aug2014 |
PROBLEM
The Service Brake Control Valve has a high bias to the left hand tandem on certain 160M Motor Graders. This can be a contributing factor to premature brake failures when brakes are partially applied to modulate speed. The failures are typically found in applications while roading in hilly terrain. The result of the failure is service brake friction discs overheat, warp, or fracture. Overheating of the brake discs can be detected by the smell of burnt tandem oil, complaints of noisy brakes, grabbing brakes, or locked up brakes. |
AFFECTED PRODUCT
Model | Identification Number |
160M | B9E00162, 164, 182, 186, 193, 211-213, 219, 249-251, 288-289, 309, 324-325, 331 |
PARTS NEEDED
Qty |
Part Number | Description |
8 | 3K0360 | SEAL-O-RING |
10 | 6V8398 | SEAL-O-RING-ORFS |
1 | 3557411 | VALVE GP-BRAKE-A |
1 | BULK_OIL | Hydraulic Oil (19 Liters) or 5 gallons |
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
Refer to the following instructions and images to replace the existing brake valve with the low bias brake valve. Refer to the appropriate Service Manuals if/as necessary. Reference: Operation and Maintenance Manual, "Lubricant Viscosities" Reference: Operation and Maintenance Manual, "Capacities (Refill)" Reference: Testing and Adjusting, "Brake System Air - Purge" 160M RENR9727 Disassembly and Assembly - "Control Valve (Brake)" |
SERVICE CLAIM ALLOWANCES
0-36 mo |
||||||
37-60 mo |
NOTE: This is a 3.0-hour job | ||||||
Note: Bulk Hydraulic and Tandem oil are only offered for machines up to 5,000 hours |
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
Low Bias Valve Replacement 1. Depress brake pedal repeatedly until the brake accumulator is drained of pressurized oil. 2. Install a vacuum cap tool onto the hydraulic tank and pressurize (refer to Disassembly and Assembly "Control Valve (Brake)"). Note: Until the 14M and 16M manual is updated, refer to the 140M and 160M D&A. |
3. Remove the covers directly in front of the cab. 4. Remove and cap any hoses in the way of the Brake Control Valve, if needed. 5. Remove and cover or cap all six tubes going to the 308-9523 Brake Control Valve. a. Note: You can use small cable straps around the steel Tubes behind the nut to keep them from sliding under the cab if you are not using caps. |
6. Remove the two brake control valve mounting bolts. 7. Remove the brake control valve and place the valve into a vice. 8. Remove all fittings and connectors from the valve and replace the 3K-0360 Seals on the fittings. Remove the 6V-8398 Seals at this time. 9. Install all fittings and connectors to the 355-7411 Brake Valve but do not tighten at this time. 10. Install the 355-7411 Brake Valve on the machine using the two original mounting bolts. 11. Assemble the six tubes, from Step #5, back to the loose fittings and connections. Tighten the fittings, connections, and Tubes at this time. a. Note: Remove any cable straps that may have been added from Step #5 12. Remove Tooling (A). 13. Check hydraulic oil level, fill as needed. 14. Start machine and let engine and hydraulic oil stabilize. 15. Check the brake valve for leaks. 16. Depress brake pedal several times to verify the brake accumulator is charged and the brake pedal is responding to movement. 17. Shut off machine. 18. Bleed brakes according to Testing and Adjusting "Brake System Air ? Purge" 19. Reinstall the cover(s) that were removed in Step #3. |
Image1.3.1 |