PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING ADDITIONAL UPDATES ON CERTAIN 770G AND 772G OFF-HIGHWAY TRUCKS

PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING ADDITIONAL UPDATES ON CERTAIN 770G AND 772G OFF-HIGHWAY TRUCKS - MULTIPLE REPAIRS

Usage:

TEBE0613-02

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23Dec2013

(Revised 24Jul2014)

D-546

O-560

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING ADDITIONAL UPDATES ON CERTAIN 770G AND 772G OFF-HIGHWAY TRUCKS - MULTIPLE REPAIRS
4310 3258 3256 3281 1408 1401 1402 4220 7254 1920 1901 7301 7510 7540 7857 7481 1273		PI32280

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32280" 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 "PI32280" 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:

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 23Dec2013 (Revised 02Jul2014) Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
30Jun2014	31Dec2014

PROBLEM

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There are certain loose, interference, and malfunctioning issues noticed which may need few parts change in certain components that may cause failure on certain 770G and 772G Off-Highway Trucks.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
770G	ECM00153-00174
772G	LTS00254-00274

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*****Group 2*****
770G	ECM00176-00186
772G	LTS00275-00288

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*****Group 3*****
770G	ECM00187-00188

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*****Group 4*****
770G	ECM00189-00190
772G	LTS00289-00291

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*****Group 5*****
770G	ECM00191

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*****Group 6*****
770G	ECM00192
772G	LTS00292-00293, 299-300

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*****Group 7*****
772G	LTS00301-00306, 308-313

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*****Group 8*****
770G	ECM00225

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1S0994	CLIP-LOOP
2	2V1771	GROMMET
1	3E6328	ALARM GP-BASIC
1	4P7581	CLIP-LADDER
1	5P4484	PLUG-STOR
1	6D4246	CLIP-LOOP
10	7K1181	STRAP-CABLE
1	7M8485	SEAL-O-RING
2	8S0948	CLIP
1	8T0070	BOLT
2	8T4121	WASHER-HARD
1	8T4133	NUT
4	8T4139	BOLT-HEX HEAD
1	8T4196	BOLT-HEX HEAD
2	9X3402	SOCKET-CONNECTOR
1	1552270	PLUG KIT-CONN
4	1783336	NUT-HEX FLANGE
2	2905562	MOUNT-DUAL
1	2941873	BRACKET AS
2	3139198	CLIP-LOOP
1	3189091	HOSE AS
1	3240845	PLATE AS
1	3240867	PLATE
6	3537957	GROMMET
1	3604923	HARNESS AS.
1	3690805	ADDITIVE-COOLANT
1	3983632	CABLE AS
4	4171719	PLATE
1	4172990	SENDER AS-F LVL
1	4374231	SOFTWARE GP-ELEK
1	4397527	SOFTWARE GP-ELEK
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.
*****Group 2*****
2	1S0994	CLIP-LOOP
2	2V1771	GROMMET
1	3E6328	ALARM GP-BASIC
1	4P7581	CLIP-LADDER
1	5P4484	PLUG-STOR
1	6D4246	CLIP-LOOP
10	7K1181	STRAP-CABLE
1	7M8485	SEAL-O-RING
2	8S0948	CLIP
1	8T0070	BOLT
2	8T4121	WASHER-HARD
1	8T4133	NUT
4	8T4139	BOLT-HEX HEAD
1	8T4196	BOLT-HEX HEAD
2	9X3402	SOCKET-CONNECTOR
1	1552270	PLUG KIT-CONN
4	1783336	NUT-HEX FLANGE
2	2905562	MOUNT-DUAL
1	2941873	BRACKET AS
2	3139198	CLIP-LOOP
1	3189091	HOSE AS
1	3240845	PLATE AS
1	3240867	PLATE
6	3537957	GROMMET
1	3604923	HARNESS AS.
1	3690805	ADDITIVE-COOLANT
1	3983632	CABLE AS
4	4171719	PLATE
1	4374231	SOFTWARE GP-ELEK
1	4397527	SOFTWARE GP-ELEK
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.
*****Group 3*****
2	1S0994	CLIP-LOOP
2	2V1771	GROMMET
1	3E6328	ALARM GP-BASIC
1	4P7581	CLIP-LADDER
1	5P4484	PLUG-STOR
1	6D4246	CLIP-LOOP
10	7K1181	STRAP-CABLE
1	7M8485	SEAL-O-RING
2	8S0948	CLIP
1	8T0070	BOLT
2	8T4121	WASHER-HARD
1	8T4133	NUT
4	8T4139	BOLT-HEX HEAD
1	8T4196	BOLT-HEX HEAD
2	9X3402	SOCKET-CONNECTOR
1	1552270	PLUG KIT-CONN
4	1783336	NUT-HEX FLANGE
2	2905562	MOUNT-DUAL
1	2941873	BRACKET AS
2	3139198	CLIP-LOOP
1	3240845	PLATE AS
1	3240867	PLATE
6	3537957	GROMMET
1	3604923	HARNESS AS.
1	3690805	ADDITIVE-COOLANT
1	3983632	CABLE AS
4	4171719	PLATE
1	4374231	SOFTWARE GP-ELEK
1	4397527	SOFTWARE GP-ELEK
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.
*****Group 4*****
2	1S0994	CLIP-LOOP
2	2V1771	GROMMET
1	3E6328	ALARM GP-BASIC
1	4P7581	CLIP-LADDER
1	5P4484	PLUG-STOR
1	6D4246	CLIP-LOOP
10	7K1181	STRAP-CABLE
1	7M8485	SEAL-O-RING
2	8S0948	CLIP
1	8T0070	BOLT
2	8T4121	WASHER-HARD
1	8T4133	NUT
4	8T4139	BOLT-HEX HEAD
1	8T4196	BOLT-HEX HEAD
2	9X3402	SOCKET-CONNECTOR
1	1552270	PLUG KIT-CONN
2	2905562	MOUNT-DUAL
1	2941873	BRACKET AS
2	3139198	CLIP-LOOP
6	3537957	GROMMET
1	3604923	HARNESS AS.
1	3690805	ADDITIVE-COOLANT
1	3983632	CABLE AS
4	4171719	PLATE
1	4374231	SOFTWARE GP-ELEK
1	4397527	SOFTWARE GP-ELEK
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.
*****Group 5*****
2	1S0994	CLIP-LOOP
2	2V1771	GROMMET
1	4P7581	CLIP-LADDER
1	5P4484	PLUG-STOR
1	6D4246	CLIP-LOOP
10	7K1181	STRAP-CABLE
1	7M8485	SEAL-O-RING
2	8S0948	CLIP
1	8T0070	BOLT
2	8T4121	WASHER-HARD
1	8T4133	NUT
4	8T4139	BOLT-HEX HEAD
1	8T4196	BOLT-HEX HEAD
2	2905562	MOUNT-DUAL
1	2941873	BRACKET AS
2	3139198	CLIP-LOOP
6	3537957	GROMMET
1	3604923	HARNESS AS.
1	3690805	ADDITIVE-COOLANT
1	3983632	CABLE AS
4	4171719	PLATE
1	4374231	SOFTWARE GP-ELEK
1	4397527	SOFTWARE GP-ELEK
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.
*****Group 6*****
2	1S0994	CLIP-LOOP
2	2V1771	GROMMET
1	4P7581	CLIP-LADDER
1	5P4484	PLUG-STOR
1	6D4246	CLIP-LOOP
10	7K1181	STRAP-CABLE
1	7M8485	SEAL-O-RING
2	8S0948	CLIP
1	8T0070	BOLT
2	8T4121	WASHER-HARD
1	8T4133	NUT
1	8T4196	BOLT-HEX HEAD
2	2905562	MOUNT-DUAL
1	2941873	BRACKET AS
2	3139198	CLIP-LOOP
6	3537957	GROMMET
1	3604923	HARNESS AS.
1	3690805	ADDITIVE-COOLANT
1	3983632	CABLE AS
4	4171719	PLATE
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.
*****Group 7*****
1	5P4484	PLUG-STOR
1	7M8485	SEAL-O-RING
1	8T0070	BOLT
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.
*****Group 8*****
This Group does not have any parts.

ACTION REQUIRED

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This program involves 12 various Rework Procedures 1 to 12. Not all machines require all Rework Procedures. The affected machines are divided into 8 serial number groups. Please refer to the table in Image 1, in order to determine what Rework Procedures are required for each serial number group of machines. Refer to the attached Rework Procedures.

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Image1

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 9.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 8.5-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 7.5-hour job for Group 3

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 7.0-hour job for Group 4

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 6.5-hour job for Group 5

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 6*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 6.0-hour job for Group 6

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 7*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 7

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 8*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 8

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR PERFORMING ADDITIONAL UPDATES ON CERTAIN 770G AND 772G OFF-HIGHWAY TRUCKS - MULTIPLE REPAIRS

MODELS INVOLVED - CERTAIN 770G AND 772G OFF-HIGHWAY TRUCKS

Dear Cat Product Owner:

Certain components on the above-mentioned machines need to be inspected and reworked or replaced as necessary. 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.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 23Dec2013 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 23Dec2013 Service Letter

Rework Procedure

Group Number 1

Refer to the table in the "Action Required" section in order to determine which rework items are to be applied for which group of machines. An item marked with an "X" indicates the rework item is to be applied.

For the machines covered under Group 1 perform all 12 Rework Procedures given below:

Rework Procedure 1 - Steering Column Joint Loose Check:

The 162-8551 Universal Joint on the steering column needs to be inspected to ensure that both 099-3649 Bolts and 131-3540 Nuts are installed and tightened to the correct tightening specification. Tighten the nut and bolt to a specified torque of 30.0 +/- 2.5 N.m (22.0 +/- 2.0 lb ft). Refer to Image1.1.1.

Image1.1.1

Rework Procedure 2 - Check Differential Yoke Bolt:

Perform static check to see if the 8T-0070 Bolt (M20) is loose, refer to Image1.2.1 for the location of bolt. Follow the procedure below to inspect and retighten the bolt if required:

a. Remove drive shaft (2). Refer to UENR1126, "Disassembly and Assembly", "Drive Shaft (Rear) - Remove and Install". Refer to Image1.2.2.

b. Check the tightness of the 8T-0070 Bolt by applying a tightening specification of of 450 N.m (332 lb ft). The bolt should not rotate. If the bolt is found to be loose, remove the 8T-0070 Bolt and replace it by a new one and reuse the same 348-4337 Retainer and 348-4649 Shim so that adjustment is not affected. The tightening specification for the 8T-0070 Bolt is 520 +/- 70 N.m (384 +/- 52 lb ft). Tighten the drive shaft bolts (1) as per specifications below.

- Tightening specification for the 0S-1604 Bolt (770G) is 156 +/- 7 N.m (115 +/- 5 lb ft)
- Tightening specification for the 6V-3811 Bolt (772G) is 160 +/- 15 N.m (118 +/- 11 lb ft).

c. Clean up the internal thread (M20 x 2.5) of the pinion to ensure good thread contact.

d. Apply red Loctite 271 to the threads of the new bolt. Order from local Loctite supplier 154-9731 and 155-0693 Thread Lock are no longer available in the Caterpillar ordering system.

e. Replace 9S-4181 Fill Plug with a new 5P-4484 Plug (magnetic).

f. Inspect the magnetic fill plug daily for one week and then weekly up to 500 hours to determine if debris is generated rapidly. This can become a regular check item if the customer agrees.

g. Take good photos of the bolt and threads. Send the photos to Caterpillar to determine if return is needed.

h. If not loose, stop and install the drive shaft and tighten the drive shaft bolts (1) to the following specification:

- Tightening specification for the 770G (0S-1604 Bolt) is 156 +/- 7 N.m (115 +/- 5 lb ft)
- Tightening specification for the 772G (6V-3811 Bolt) is 160 +/- 15 N.m (118 +/- 11 lb ft).

Image1.2.1

Image1.2.2

Rework Procedure 3 - Alternator Cable Terminal Breaks:

Refer to SEPD1623, Service Magazine, "A New Cable Assembly with Improved Routing for Battery Wiring Group Is Now Used on Certain 770G and 772G Off-Highway Trucks", for additional instructions.

Note: Refer to Image1.3.1. and 1.3.2. for the alternate method of routing the alternator cable in the battery box.

Rework Procedure 4 - Replace Mudguard Mounting Plates:

Refer to SEPD1635, Service Magazine, "A New Plate Improves the Mud Guard Mounting on Certain 770G and 772G Off-Highway Trucks", for additional instructions.

Rework Procedure 5 - RHS Hoist Cylinder Interferes With Brake Oil Temperature Sensor Harness:

Refer to SEPD1629, Service Magazine, "The Chassis Wiring Group Has Been Updated on Certain 770G and 772G Off-Highway Trucks", for additional instructions.

Rework Procedure 6 - Phosphate Additive To Be Added in Radiator:

Add one bottle of 369-1805 Additive to the cooling system in order to passivate the aluminum radiator used. This is one time only.

Rework Procedure 7 - Battery Damaged By Step Mounting Bolt:

Check if battery is damaged by the 8T-4139 Step Mounting Bolt. If damage is found, grind the bolt short or replace by a correct 8T-4139 Bolt of 30mm in order to avoid further interference. Replace the battery if needed. A separate warranty claim will need to be filed. Refer to Image1.3.3 and 1.3.4.

Image1.3.1

Image1.3.2

Image1.3.3

Image1.3.4

Rework Procedure 8 - Fuel Priming Not Working:

The software needs to be updated. Refer to SEPD1669, Service Magazine, "New Engine Software Is Available for the Engines in Certain 770G and 772G Off-Highway Truck", for additional information.

Rework Procedure 9 - Replace the Alarm Group:

Refer to REHS7987, Special Instruction, "Procedure to Install the Alarm Group on Certain Off-Highway Trucks", for additional information.

Rework Procedure 10 - Replace ECM Cover Plates:

Refer to SEPD1625, Service Magazine, "Improved ECM Cover Plates are Now Used on Certain 770G and 772G Off-Highway Trucks", for additional information.

Rework Procedure 11 - Grease Line to Steering Ball Stubs Interfere With Engine Oil Pan:

Refer to SEPD1617, Service Magazine, "Improved Hose Routing Reduces Interference for the Central Lubrication Lines Group on the 770G and 772G Off-Highway Truck", for additional information.

Rework Procedure 12 - Replace Fuel Level Sender Assembly:

Refer to SEPD1611, Service Magazine, "A New Fuel Level Sender Assembly for the Fuel Tank Group is Now Used on Certain 770G and 772G Off-Highway Trucks", for additional information.

Group Number 2

For the machines covered under Serial Number Group2 perform the instructions from Rework Procedures 1 to 11, provided in the Group Number 1 Rework Procedure.

Group Number 3

For the machines covered under Serial Number Group3 perform the instructions from Rework Procedures 1 to 10, provided in the Group Number 1 Rework Procedure.

Group Number 4

For the machines covered under Serial Number Group4 perform the instructions from Rework Procedures 1 to 9, provided in the Group Number 1 Rework Procedure.

Group Number 5

For the machines covered under Serial Number Group5 perform the instructions from Rework Procedures 1 to 8, provided in the Group Number 1 Rework Procedure.

Group Number 6

For the machines covered under Serial Number Group6 perform the instructions from Rework Procedures 1 to 6, provided in the Group Number 1 Rework Procedure.

Group Number 7

For the machines covered under Serial Number Group7 perform the instructions in Rework Procedure 1 and 2, provided in the Group Number 1 Rework Procedure.

Group Number 8

For the machines covered under Serial Number Group8 perform the instructions in Rework Procedure 1, provided in the Group Number 1 Rework Procedure.