PRODUCT SUPPORT PROGRAM FOR REWORKING THE HYDRAULIC RETURN HOSE AND TUBE FROM THE MAIN CONTROL VALVE TO THE THERMAL BYPASS VALVE ON CERTAIN 559D, 579D, 2384D, AND 2484D KNUCKLEBOOM LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE HYDRAULIC RETURN HOSE AND TUBE FROM THE MAIN CONTROL VALVE TO THE THERMAL BYPASS VALVE ON CERTAIN 559D, 579D, 2384D, AND 2484D KNUCKLEBOOM LOADERS

Usage:

TEBE8920-00

Show/hide table

16Apr2019

U-233

Show/hide table

Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE HYDRAULIC RETURN HOSE AND TUBE FROM THE MAIN CONTROL VALVE TO THE THERMAL BYPASS VALVE ON CERTAIN 559D, 579D, 2384D, AND 2484D KNUCKLEBOOM LOADERS
3004		PS46231

Show/hide table

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 either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46231" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

TERMINATION DATE

30Apr2021

PROBLEM

Show/hide table

The existing return hose, pipe, and connection hose can fail at the thermal bypass valve on certain 559D, 579D, 2384D, and 2484D Knuckleboom Loaders. If the existing hose fails, it will leak hydraulic fluid.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
2384D	KP500200-00249
2484D	KP700250-00271
559D	KL500100-00294
579D	KL700150-00177

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
2	4J0527	SEAL-O-RING
1	6V1867	CLIP
1	6V1868	CLIP
1	6V1869	GROMMET
2	7K1181	STRAP-CABLE
1	8T4139	BOLT-HEX HEAD
1	8T4223	WASHER-HARD
1	9R2640	BOSS
1	1158645	GUARD
1	5738897	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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

Show/hide table

Refer to the attached Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 5.0-hour job
Note: Up to $80 US Dollars is allowed to replace any lost oil when performing the program as a Before Failure repair. Note: Up to $200 US Dollars is allowed to replace any lost oil when performing the program as an After Failure repair.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

1. Drain the oil from the hydraulic tank. Refer to the machines Operation and Maintenance Manual for the draining and filling procedure of the hydraulic tank. Ensure the container that the oil is being drained into is 100% clean and moisture free.

2. Remove the existing 468-8835 and 5P-1293 Hoses, 466-6749 and 371-4606 Tubes, from the 466-6746 Filter Group. Retain the split flanges and all hardware for later reuse.

Note: Pay attention to the bolts used at the thermal bypass and return manifold as they are different lengths. The O-ring seals will not be reused.

3. Remove the existing hose mounting boss from the frame after marking for, or welding on, the new 9R-2640 Boss. The existing boss is used to measure the location for the new 9R-2640 Boss. Once measured, the new 9R-2640 Boss can be welded onto the frame and painted, once cooled. Refer to Image1.1.1.

Image1.1.1

4. Route the new 573-8897 Hose Assembly and install a new 4J-0527 O-Ring Seal on both ends. Secure the flange clamps.

5. Install new 6V-1867 and 6V-1868 Clips, and 6V-1869 Grommet, to secure the 573-8897 Hose Assembly to the new 9R-2640 Boss. The 573-8897 Hose Assembly should NOT make contact with any of the frame members or other hoses. Adjust the 573-8897 Hose Assembly, as needed, to ensure the life of the new hose.

6. Install a new 115-8645 Guard and secure with new 7K-1181 Cable Straps to ensure that there is no damage that can occur where the new hose runs though the frame to the thermal bypass valve. Refer to Image1.2.1

7. Once the new hose is installed the hydraulic tank can be re-filled using the fill pump. This pump is not intended to operate for long periods of time. After every 5 gallons the pump should be allowed to cool before operation continues.

8. Start the machine and let idle for 5 minutes to purge any air out of the system before operating. During this time check for any leaks and repair as needed.