PRODUCT SUPPORT PROGRAM FOR REPLACING THE HOIST, BRAKE CHARGE, AND BRAKE COOLING PUMP GROUPS ON CERTAIN 777G OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HOIST, BRAKE CHARGE, AND BRAKE COOLING PUMP GROUPS ON CERTAIN 777G OFF-HIGHWAY TRUCKS

Usage:

TEBE6727-01

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29Nov2017

(Revised 29Mar2019)

N01H
N020

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE HOIST, BRAKE CHARGE, AND BRAKE COOLING PUMP GROUPS ON CERTAIN 777G OFF-HIGHWAY TRUCKS
5073		PS90801

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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 "PS90801" 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 29Nov2017 Service Letter. Changes have been made to extend the Termination Date and Service Claim Allowances Product smu/age hours.

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TERMINATION DATE

30Nov2020

PROBLEM

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The existing brake charge pump can fail on certain 777G Off-Highway Trucks. If the existing brake charge pump fails, it will lead to excessive accumulator charge time.

AFFECTED PRODUCT

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Model	Identification Number
777G	RDR00154-00156, 176-178, 212, 217, 379-380, 383

PARTS NEEDED

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Qty	Part Number	Description
1	4J0520	SEAL-O-RING
2	4J0524	SEAL-O-RING
13	5P1295	HOSE BK
4	6C3241	BOLT
1	6J2680	SEAL-O-RING
1	6V8001	SEAL-O-RING
1	8F8733	SEAL-O RING
4	8T4183	BOLT-HEX HEAD
4	8T4223	WASHER-HARD
2	2094577	CLAMP-T'BOLT
1	2147568	SEAL-O-RING-STOR
1	2287093	SEAL-O-RING-ORFS
1	2933645	ELEMENT AS.-HYD
1	3694109	KIT-REPAIR
1	4859674	PUMP GP-GR A
1	4908129	TUBE AS
1	4973512	PUMP GP-GR B
1	5405051	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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Replace the existing 460-7292 Brake Hoist Pump, 460-7283 Brake Cooling Pump, and 455-9315 Brake Charge Pump with a new 485-9674 Hoist Pump Group and 497-3512 Tandem Brake Cooling/Charge Pump Group. Installation of a new hose and tube assembly will be needed to complete this 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%
0-30000 hrs, 0-84 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 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.

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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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Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Refer to the Service Manual if/as necessary.

Refer to the Operation and Maintenance manual, for your machine, in order to release system pressure.

Notes:

- This rework is for the 777G hoist and brake pumps.
- Only one tube and one hose will be replaced. The others will be reused.
- Some hardware and fittings to be reused so do not discard until fit-up is complete.

1. Remove pumps, suction tubes, and discharge hoses; indicated suction tube and discharge hose will be replaced while the remaining clips, hardware, other hoses, and tube will be reused. Refer to Image1.2.1.

Image1.2.1

2. Assemble the O-ring seal provided in the rear housing of the 485-9674 Gear Pump Group onto the new 497-3512 Gear Pump Group. Refer to Image1.3.1.

Image1.3.1

3. Connect the 497-3512 Gear Pump Group to the new 485-9674 Gear Pump Group using four new 5P-2566 Bolts and four new 8T-4223 Hard Washers. Refer to Image1.4.1.

Image1.4.1

4. Assemble the new 8F-8733 O-Ring Seal to the 485-9674 Gear Pump Group. Refer to Image1.5.1.

Image1.5.1

5. Assemble the pump stack to the ITG reusing four 8T-7338 Bolts and four 9X-8257 Hard Washers. Refer to Image1.6.1.

Image1.6.1

6. Reconnect the suction tubes using a new sleeve composed of a 13cm piece of 5P-1295 Hose and two 209-4577 Clamps on the new 490-8129 Tube Assembly. Refer to Image1.7.1.

Image1.7.1

7. Reconnect the hoist pump discharge hose. Refer to Image1.8.1.

Image1.8.1

8. Reconnect the brake cooling pump discharge hose, replacing the existing bolts with four new 8T-4183 Bolts. Refer to Image1.9.1 and 1.9.2.

Note: The other end may need to be adjusted to achieve necessary slack for the pump end. Refer to Image1.9.1.

Note: To achieve necessary slack in the hose, the coupling may need to be loosened and angled.

Image1.9.1

Image1.9.2

9. Reconnect the brake charge pump discharge hose. Refer to Image1.10.1.

Image1.10.1

10. Ensure all connections are tight.

11. Replace the 293-3645 Element Assembly.

12. Replace the brake charge pump valve screen which is found in the 369-4109 Repair Kit. Refer to Image1.11.1.