PRODUCT SUPPORT PROGRAM FOR REPLACING THE BATTERY BOX ON CERTAIN 775G OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BATTERY BOX ON CERTAIN 775G OFF-HIGHWAY TRUCKS

Usage:

TEBE2566-00

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23Jan2015

Q630
X260

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE BATTERY BOX ON CERTAIN 775G OFF-HIGHWAY TRUCKS
7257		PS90449

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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 "PS90449" 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 battery box can allow heat to be transferred to the batteries on certain 775G Off-Highway Trucks. If enough heat were to transfer to the batteries, it could reduce the life of the batteries.

AFFECTED PRODUCT

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Model	Identification Number
775G	RFM00353-00357, 390-391

PARTS NEEDED

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Qty	Part Number	Description
1	4201533	SUPPORT 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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Replace the existing battery box with a new 420-1533 Support Assembly (battery box). Refer to service manual and 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%
0-800 hrs, 0-6 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-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. Raise the body on the truck to the fully raised position and install the body retaining pins.
2. Shut the truck off and turn the master disconnect located in the front service center box off.

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3. Disconnect the positive and negative leads going into the battery box.
4. Remove and retain the two 4S-1962 P-clips used to secure the positive lead to the battery box.
5. Remove the four bolts located at the corners of the battery box.
6. Attach tooling and lift the battery box out of the truck and place it on the ground.

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7. Remove the three top plates from the existing battery box and the three top plates with insulation from the new battery box.
8. Remove the jumper battery cable, unbolt the positive and negative leads from the battery box, remove the battery hold down, and remove the batteries from the existing battery box.
9. Install the removed parts in Step 8 into the new 420-1533 Support Assembly (battery box).
10. Install the three top plates with insulation on the new battery box.
11. Attach tooling to lift the battery box into the truck.
12. Secure the battery box in the truck frame with the four existing bolts. Tighten the bolts to a torque of 100 +/- 20 Nm (74 +/- 15 lb ft).
13. Install the existing 4S-1962 P-clips to the battery box.
14. Connect positive and negative leads going into the battery box.
15. Turn the mater disconnect switch located in the front service center on.
16. Start the truck, remove the body retaining pins, and lower the body.