Product Support Program For Replacing The Restrictive Drain Lines And Fittings Associated With The Rockford Fan On Certain 768C, 769C, 771C, 772B, 773B, And 775B Off-Highway Trucks Caterpillar

Product Support Program For Replacing The Restrictive Drain Lines And Fittings Associated With The Rockford Fan On Certain 768C, 769C, 771C, 772B, 773B, And 775B Off-Highway Trucks

Usage:

@media screen { div.divFooter { display: none; } } @media print { div.divFooter { position: fixed; bottom: 0; right: 0; } }

Caterpillar: Confidential Yellow

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.

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS8899" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the February 25, 1997 Service Letter. Changes have been made to the Affected Product.

Termination Date

February 28, 1998

Problem

The drain line and fittings for the Rockford fan drive on certain 768C, 769C, 771C, 772B, 773B, and 775B Off-Highway Trucks may not allow proper drain of the lube oil. As a result, oil leakage at the shaft seals occurs at low hours.

Affected Product
Model & Identification Number

Group 1

768C (02X1-09999)

769C (01X1-09999)

771C (3BJ1-09999)

Group 2

772B (64W1-09999)

773B (63W1-09999)

775B (7XJ1-09999)

Parts Needed

Group 1

2 - 6D4246 Clip

1 - 3J1907 Seal-O-Ring

1 - 3K0360 Seal-O-Ring

1 - 2M9780 Seal-O-Ring

1 - 9M9647 Seal-O-Ring

2 - 4N1418 Gasket

1 - 4P8511 Hose Assembly

1 - 5P4295 Clip

1 - 8T4223 Washer

1 - 8T6338 Tee-O-Ring

1 - 6V8397 Seal-O-Ring

2 - 6V8398 Seal-O-Ring

1 - 6V8625 Elbow

1 - 6V8638 Connector

1 - 6V8936 Reducer Assembly

1 - 6V9837 Tee

1 - 6V9873 Connector

1 - 0985708 Tie

1 - 1010387 Connector

1 - 1167056 Hose Assembly

1 - 1215756 Seal Kit

1 - 1255050 Plug

1 - 1255053 Hose Assembly

PARTS NEEDED CONT.

Group 2

1 - 7C0307 Gasket

1 - 8C6872 Connector

1 - 6D4246 Clip

1 - 3K0360 Seal-O-Ring

1 - 2M9780 Seal-O-Ring

2 - 4N1418 Gasket

1 - 6N7854 Cover

1 - 4P8511 Hose Assembly

1 - 5P3501 Adapter

1 - 5P4295 Clip

1 - 5S7383 Bolt

1 - 8T4223 Washer

1 - 8T4896 Washer

1 - 1V6645 Spacer

1 - 6V4245 Elbow

1 - 6V8397 Seal-O-Ring

2 - 6V8398 Seal-O-Ring

1 - 6V8625 Elbow

1 - 6V8638 Connector

1 - 6V8936 Reducer Assembly

1 - 6V9837 Tee

1 - 6V9873 Connector

1 - 0985708 Tie

1 - 1010387 Connector

1 - 1255057 Hose Assembly

1 - 304555 Hose Assembly

Action Required

See attached rework procedure.

Service Claim Allowances

NOTE: If an oil leak is found, allow 4 hours labor to seal the leak.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Installing Reduced Restriction Drain Lines - 3408 Engines

NOTE: Reference Service Magazines dated Febrauary 26, 1996, April 01, 1996, and April 15, 1996.

1. Remove crossbar adjacent to radiator inlet tubes - note the shim position.

2. Drain the coolant below the radiator inlet tubes. Remove the bolts from the radiator inlet tubes at the radiator. Loosen the hose clamp on engine side and rotate the tubes out of the way of the fan guard.

3. Remove the two fan guards and bolts attaching the fan to the drive. Lay the fan in the shroud area.

4. Drain the oil from the engine oil pan down to the 1011927 Plug (retained with one bolt). Disconnect the two oil lines going into the 7X2459 Tee at the tee only. Remove the tee from the 1011927 Plug and remove the 3Y2888 Connector and save for later use.

5. Remove the fan belt tightener spring and bracket.

6. Remove the other end of the 1019567 Drain Hose Assembly from the top of the 6I4427 Drive Assembly along with the 6V8723 Elbow. Also remove the miscellaneous hose clips.

7. Remove the 0910843 Hose Assembly and the 6V8934 Reducer, 6V8715 Connector, 8C6865 Connector and the 6V9836 Tee from the 1010329 Control Valve Assembly and the front left side of the block. From the left side of the 6I4427 Drive Assembly, remove the 6V8636 Connector and the 8W5426 Hose Assembly.

8. Inspect the 6I4427 Drive Assembly for leakage. If the drive is WET from oil in either shaft seal area, remove the drive at this time for replacement or rebuild. See SENR8603-01 for rebuild instructions.

9. Assemble the block oil supply at the front left side of the block using a 6V8638 Connector, a 2M9780 Seal, a 6V8398 Seal, a 6V9837 Tee and Two 6V8398 Seals.

10. In the left side of the 6I4427 Drive Assembly, insert a 6V9873 Connector using a 3J1907 Seal and a 6V8398 Seal. Install the straight end of the 4P8511 Hose Assembly into the connector.

11. Connect the other end of the 4P8511 Hose Assembly into the top of the oil supply Tee. Secure the hose to the non-metallic alternator guard using a 5P4295 Hose Clip and an 8T4223 Washer.

12. Fasten the 90 degree end of the 1255053 Hose Assembly onto the remaining end of the oil supply tee using a 6V8936 Reducer Assembly and a 6V8397 Seal. Using a 1010387 Connector and a 6V8397 Seal, connect the other end of the hose to the "NO" port of the 1010329 Control Valve Assembly.

13. Install a 6V8625 Elbow, a 3KO360 Seal and a 6V8398 Seal into the top port of the 6I4427 Drive Assembly. Fasten the straight end of the 1167056 Hose Assembly into this elbow and run the other end down the left front of the engine under the oil filters and over to the middle of the left side of the oil pan. Remove the 1011927 Plug (retained by one bolt) and insert the new 1255050 Plug sealed with a 9M9647 Seal. Connect the other end of the 1167056 Hose Assembly into the plug by an 8T6338 Tee using a 3KO360 Seal, a 3J19O7 Seal and a 6V8398 Seal. Insert the Hose coming from the "NC" port of the control valve assembly into the other port of the tee using the 3Y2888 Connector from Step 4. Affix the hose to the lower left front corner of the block using a 6D4246 Hose Clip and the old 8T4896 Washer.

14. Install the fan onto the drive and replace the fan guards.

15. Install fan belt tightener bracket and spring.

16. Install the two radiator inlet water lines using new 4N1418 Gaskets. Refill the system with coolant.

17. Install the cross brace with the shims returned to their "as found" position.

18. Top off the oil in the crankcase.

19. Start the engine and check for leaks.

20. Ensure proper fan operation by disconnecting the water temperature sensor line in the left side radiator inlet tube. Fan should go to high speed. After this modification, fan may come to a complete stop under low engine coolant temperature conditions. This is normal and should not be considered a problem unless the fan does not come on as required at higher engine coolant temperatures.

Installing Reduced Restriction Drain Lines - 3412 Engines

NOTE: Reference Service Magazines dated Febrauary 26, 1996, April 01, 1996, and April 15, 1996.

1. Remove crossbar adjacent to radiator inlet tubes - note the shim position.

2. Drain the coolant below the radiator inlet tubes. Remove the bolts from the radiator inlet tubes at the radiator. Loosen the hose clamp on the engine side and rotate the tubes out of way of the fan guard.

3. Remove the two fan guards and bolts attaching the fan to the drive. Lay the fan in the shroud area.

4. Drain the oil from the engine oil pan down to the two bolt cover on the left side of the engine oil pan near the front. Disconnect the two oil lines going into the 7X2459 Tee at the tee only. Remove the tee from the 1011927 Plug.

5. Remove the fan belt tightener spring and bracket.

6. Remove the other end of the 8W3101 Drain Hose Assembly from the top of the 6I4427 Drive Assembly along with the 6V8723 Elbow. Also remove the miscellaneous hose clips.

NOTE: Older models have a 9C7335 Hose instead of an 8W3101.

7. Remove the 6R7451 Hose Assembly, the 6V8934 Reducer, 6V8715 Connector, 8C6865 Connector and the 6V9836 Tee from the 1010329 Control Valve Assembly and the front left side of the block. From the left side of the 6I4427 Drive Assembly, remove the 6V8636 Connector and the 8W5426 Hose Assembly.

9. Assemble the block oil supply at the front left side of the block using a 6V8638 Connector, a 2M9780 Seal, a 6V8398 Seal, a 6V9837 Tee and Two 6V8398 Seals.

10. In the left side of the 6I4427 Drive Assembly, insert a 6V9873 Connector using a 3J1907 Seal and a 6V8398 Seal. Install the straight end of the 4P8511 Hose Assembly into the connector.

11. Connect the other end of the 4P8511 Hose Assembly into the top of the oil supply Tee. Secure the hose to the non-metallic alternator guard using a 5P4295 Hose Clip and an 8T4223 Washer.

12. Fasten the 90 degree end of the 1255057 Hose Assembly onto the remaining end of the oil supply tee using a 6V8936 Reducer Assembly and a 6V8397 Seal. Using a 1010387 Connector and a 6V8397 Seal, connect the other end of the hose to the "NO" port of the 1010329 Control Valve Assembly.

13. Install a 6V8625 Elbow, a 3KO360 Seal and a 6V8398 Seal into the top port of the 6I4427 Drive Assembly. Fasten the straight end of the 1304555 Hose Assembly into this elbow and run the other end down the front left of the engine. Remove the 4NO794 two bolt cover and replace with a 6N7854 Cover and 7CO307 Gasket. Install an 8C6872 Connector and a 6V8398 Seal. Connect the 90 degree end of the hose to this connector. Affix the hose to the lower left front of the block using a 6D4246 Hose Clip with a 5S7383 Bolt, a 5P1075 Washer and a 1V6645 Spacer.

NOTE: NEW POSITION FOR CLAMPING HOSE - Illustration 3

At the middle of the oil pan do the following to attach the remaining drain hose to the pan. Insert a 6V4245 Elbow with a 5P3501 Adapter and a 3J19O7 Seal. Reinsert the Hose coming from the "NC" port of the control valve assembly into the elbow discarding the 3Y2888 Connector.