PRODUCT SUPPORT PROGRAM FOR INSTALLING 352-6554 VALVE GROUPS ON CERTAIN 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING 352-6554 VALVE GROUPS ON CERTAIN 775F OFF-HIGHWAY TRUCKS

Usage:

TEBE2462-00

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06Jan2015

Q630
Q631

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING 3526554/">352-6554 VALVE GROUPS ON CERTAIN 775F OFF-HIGHWAY TRUCKS
4261 4257 5117		PS90445

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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 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 "PS90445" 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

31Jul2015

PROBLEM

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The existing service and parking brake group can exhibit brake dragging on certain 775F Off-Highway Trucks. If continuous brake dragging occurs in the service and park brake groups, it can lead to high brake oil temperature and logged events.

AFFECTED PRODUCT

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Model	Identification Number
775F	DLS01337, 1360-1361, 1397, 1403, 1456-1457, 1460-1461

PARTS NEEDED

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Qty	Part Number	Description
4	2M9780	SEAL-O-RING-STOR
1	3D2824	SEAL-O-RING-STOR
4	3K0360	SEAL-O-RING
2	3W9670	BOSS
4	6D4636	CLIP-LOOP
2	6V8629	ADAPTER-ELBOW
2	6V8640	ADAPTER-STR
15	6V9746	SEAL-O-RING-ORFS
2	6V9839	ADAPTER-TEE
1	6V9853	ADAPTER-ELBOW
2	6V9874	ADAPTER-STR
2	7I1036	ADAPTER-STR
1	7I8310	ADAPTER-STR
2	7L6463	SPACER
6	8T4121	WASHER-HARD
2	8T4133	NUT
2	8T4182	BOLT-HEX HEAD
2	8T5030	BOLT
2	9M8406	CLIP-LOOP
1	2617957	ADAPTER
2	2635846	BODY
2	3526554	VALVE GP-D RLF-B
2	3905013	HOSE AS
2	3907591	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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Install the new 3526554/">352-6554 Valve Groups and related parts.
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%
0-100 hrs, 0-12 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

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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).
2. Disconnect hose assembly (A) and hose assembly (B) from the brake group and remove hose assembly (A) and (B) from the truck.
3. Disconnect hose assembly (D) from adapter (E).
4. Remove adapter (E) from the slack adjuster. The adapter will not be reused. Refer to Image 1.1.1.

Image1.1.1

5. Install a 7I-8310 Adapter (1) to slack adjuster (C) with a 3D-2824 O-ring Seal (2). Tighten the 7I-8310 Adapter (1) to a torque of 110 +/- 17 Nm (81 +/- 13 lb ft).
6. Install a 261-7957 Adapter (3) to the 7I-8310 Adapter (1) with a 6V-9746 O-ring Seal (4). Tighten the 261-7957 Adapter (3) to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft). Refer to Image 1.2.1.

Image1.2.1

7. Install a 6V-8640 Adapter (5) to each side of the slack adjuster with a 2M-9780 O-ring Seal (6). Tighten the 6V-8640 Adapter (5) to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft).
8. Install a 6V-9839 Adapter (7) to each 6V-8640 Adapter with a 6V-9746 O-ring Seal (4). Tighten the 6V-9839 Adapter (7) to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft).
9. Install a 7I-1036 Adapter (8) to each of the 6V-9839 Adapters (7) with one 6V-9746 O-ring Seal (4). Tighten the 7I-1036 Adapter (6) to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft). Refer to Image 1.3.1.

Image1.3.1

10. Install a 263-5846 Body (9) to each 7I-1036 Adapter (8) with one 3K-0360 O-ring Seal (10). Tighten each 263-5846 Body (9) to a torque of 110 +/- 17 Nm (81 +/- 13 lb ft).
11. Install a 3526554/">352-6554 Valve Group (11) to each 263-5846 Body (9). Tighten the 3526554/">352-6554 Valve Group (11) to a torque of 24 +/- 3 Nm (18 +/-2 lb ft). Refer to Image 1.4.1.

Image1.4.1

12. Install a 6V-9874 Adapter (12) to each 263-5846 Body (9) with a 3K-0360 O-ring Seal (10). Tighten each 6V-9874 adapter (12) to a torque of 110 +/- 17 Nm (81 +/- 13 lb ft). Refer to Image 1.5.1.
13. Install a 390-7591 Hose (13) to each 6V-9874 Adapter (12) with a 6V-9746 O-ring Seal (4).
14. Install the opposite end of each 390-7591 Hose (13) to the 261-7957 Adapter (3) with a 6V-9746 O-ring Seal (4).
15. Tighten the swivel nut on each end of each 390-7591 (13) hose to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft). Refer to Image 1.5.1.

Image1.5.1

16. Install a 6V-9853 Adapter (14) to the 261-7957 Adapter (3) with a 6V-9746 O-ring Seal (4). Tighten the 6V-9853 Adapter (14) to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft). Refer to Image 1.6.1.
17. Install hose assembly (D) in Step 1 to the 6V-9853 Adapter (14) with a 6V-9746 O-ring Seal (4). Tighten the swivel nuts to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft). Refer to Image 1.6.1.

Image1.6.1

18. Install a 390-5013 Hose (15) to each 6V-9839 Adapter (7) with a 6V-9746 O-ring Seal (4).
19. Install a 6V-8629 Adapter (16) at each brake group with a 2M-9780 O-ring Seal (6).
20. Install the opposite of the 390-5013 Hose (15) to the 6V-8629 Adapter (16) with a 6V-9746 O-ring Seal.
21. Tighten the swivel nut on each end of each 390-5013 Hose (15) to a torque of 160 +/- 24 Nm (118 +/- 18 lb ft). Refer to Image 1.7.1 and Image 1.7.2

Image1.7.1

Image1.7.2

22. Install a 9M-8406 Clip (17) to each steel line (F) and a 6D-4636 Clip (18) to each 390-5013 Hose (15) and secure them with an 8T-4182 Bolt (19), two 8T-4121 Washers (20), a 3W-9670 Boss (21) and an 8T-4133 Nut (22). Tighten each bolt to a torque of 55 +/- 10 Nm (41 +/- 7 lb ft). Refer to Image 1.8.1.

Image1.8.1

23. Install a 6D-4636 Clip (18) to each 390-5013 Hose (15) with an 8T-5030 Bolt (23), 8T-4121 Washer (20), and 7L-6463 Spacer (24). Tighten each bolt to a torque of 55 +/- 10 Nm (41 +/- 7 lb ft). Refer to Image 1.9.1.