PRODUCT SUPPORT PROGRAM FOR REPLACING THE 0549012 CARTRIDGE ASSEMBLY FOR THE SERVICE BRAKE VALVE ON CERTAIN 785C, 789C, AND 789D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 0549012 CARTRIDGE ASSEMBLY FOR THE SERVICE BRAKE VALVE ON CERTAIN 785C, 789C, AND 789D OFF-HIGHWAY TRUCKS

Usage:

TEBE0475-01

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02Oct2013

(Revised 04Nov2013)

J183
J189
J19D
J210
J211
J217
J218
J21D
J21T
J248
J361
J363

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 0549012 CARTRIDGE ASSEMBLY FOR THE SERVICE BRAKE VALVE ON CERTAIN 785C, 789C, AND 789D OFF-HIGHWAY TRUCKS
5506 4282 4265		PS90322

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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. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90322" 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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NOTE:	This Revised Service Letter replaces the 02Oct2013 Service Letter. Changes have been made to the Affected Product and Service Claim Allowances.

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TERMINATION DATE

31Oct2014

PROBLEM

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The 2044270 Valve Group (Air Control Service Brake) can leak air through the 0549012 Cartridge on certain 785C, 789C, and 789D Off-Highway Trucks.
The leaks drain air from the reservoir when the machine is parked for a long period of time. This makes it difficult to start the trucks if they are equipped with an air starter.
To prevent air leakages, replace 0549012 Cartridge every 2000 hours.

AFFECTED PRODUCT

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Model	Identification Number
785C	APX00168-00175, 195-198, 399-401, 405, 407-413, 422-423, 432-434, 440-442, 488-493, 497-502, 517-519, 528, 532-535, 542-546, 576-580, 585-587, 590-591, 734-737, 966-967, 977, 979, 981-982, 986, 997, 1006, 1009-1014, 1270-1272, 1275-1286, 1385-1386, 1388-1395, 1399, 1408-1413, 1415-1417, 1419, 1421-1422, 1424, 1429, 1434, 1436-1438, 1445-1447, 1472, 1474, 1476, 1478, 1480, 1482, 1484, 1486, 1522-1524, 1526-1528, 1536, 1706-1714, 1719-1721, 1725-1731, 1735, 1738-1744, 1746-1747, 1764-1765, 1769-1775, 1782-1787, 1798, 1808-1810, 1822-1824, 1837-1841, 1864-1865, 1872-1874, 1880-1884, 1888-1892, 1909-1911, 1916, 1924, 1930-1946, 1950-1958, 1962-1970, 1974-1978, 1983-1987, 1990-1992, 2001-2015, 2058-2059, 2064, 2067-2073, 2075-2078, 2085, 2093-2097, 2103-2104, 2108, 2111-2112
789C	2BW00633-00634, 637-638, 641, 643-644, 648-656, 702-703, 710-711, 739, 842-845, 851-853, 1036-1038, 1507, 1509, 1520-1521, 1533, 1539, 1547-1548, 1701-1702, 1717-1718, 1803-1807, 1848-1852, 1888-1892, 1916-1920, 1926-1930, 1947-1951, 1965-1969, 1979-1983, 2003-2007, 2023-2026, 2028, 2047-2048, 2050-2052, 2077-2079
789D	SPD00182-00183, 191-192, 196, 211, 213, 215, 217-218, 238, 240, 242, 244-245, 269, 274-275, 278-279, 299, 301, 303, 305, 322, 331, 340-343, 379, 381, 383-384, 386, 404, 408

PARTS NEEDED

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Qty	Part Number	Description
1	0549012	CARTRIDGE 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 service manual if/as necessary and replace the 0549012 Cartridge.

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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%
0-60000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-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.
1. First replacement of Cartridge is allowed irrespective of hours when air leak is reported from 2044270 valve. 2.Further replacement should be done every 2000Hrs of machines operation.

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