PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HYDRAULIC TANK COVER ON CERTAIN 775F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HYDRAULIC TANK COVER ON CERTAIN 775F OFF-HIGHWAY TRUCKS

Usage:

TEBE2522-00

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06Jan2015

Q630
Q631

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HYDRAULIC TANK COVER ON CERTAIN 775F OFF-HIGHWAY TRUCKS
5056		PS90442

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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 "PS90442" 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 brake cooling return tube inside the hydraulic tank and part of the
2814551/">281-4551 Cover Assembly can crack on certain 775F Off-Highway Trucks. The existing 2814551/">281-4551 Tank Cover Assembly can be replaced with a newly designed 2814551/">281-4551 or 238-8735 Tank Cover Assembly.

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
3	2M9780	SEAL-O-RING-STOR
2	3D2824	SEAL-O-RING-STOR
2	3K0360	SEAL-O-RING
2	4J0527	SEAL-O-RING
1	4J8251	GROMMET
6	5H6005	SEAL-O RING
1	6J2680	SEAL-O RING
1	6V8397	SEAL-O-RING-ORFS
1	6V9746	SEAL-O-RING-ORFS
1	9H6454	GASKET
1	2381825	GASKET
1	2814551	COVER 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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New 238-8735 and 2814551/">281-4551 Tank Cover Assemblies for the hydraulic tank have been released. The thickness of the brake return tube assembly has increased from 1.65mm to 3.05mm. If the hydraulic tank has a broken return tube, remove the old hydraulic tank cover and replace it with the new hydraulic tank cover.

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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 8.0-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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The Rework Procedure should be done during a normal hydraulic system oil change interval as described in the Operation and Maintenance Manual, "Maintenance Interval Schedule". The work should be done in a clean environment to minimize contamination.

Refer to SEBU7794, Operation and Maintenance Manual, "773F, and 775F OFF-HIGHWAY TRUCKS".

1. Drain the hydraulic tank as described in the Operation and Maintenance Manual, "Hoist, Torque Converter and Brake Tank Oil - Change".

2. Remove the hydraulic tank cover.

3. Clean the mating surface on the tank in order to remove all gasket material and burrs on the machined surface. Use a 6V-0185 Reconditioning Disc, or similar reconditioning disc, in order to clean these surfaces.

4. Remove the sight gauge and retainer from the old hydraulic tank cover and reinstall on the new hydraulic tank cover using new seals and grommets. Refer to Image1.1.1.

Image1.1.1

5. Remove the screen assembly and associated components from the old hydraulic tank cover and reinstall on the new hydraulic tank cover. Refer to Image1.2.1.

Image1.2.1

6. Remove the filler cap, strainer, and associated components from the old hydraulic tank cover and reinstall on the new hydraulic tank cover. Refer to Image1.3.1.

Image1.3.1

7. Inspect the bottom of the hydraulic tank for debris and clean as needed.

8. Install either a 2814551/">281-4551 Tank Cover Assembly using a new 238-1825 Gasket.

9. Refill the hydraulic tank as described in the Operation and Maintenance Manual, "Hoist, Torque Converter and Brake Tank Oil - Change."