PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGE\BRAKE COOLING PUMP GROUPS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGE\BRAKE COOLING PUMP GROUPS [UEBE0013]

BRAKING SYSTEM

TANK GP

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGE\BRAKE COOLING PUMP GROUPS

UEBE0013-03

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19Dec2019

(Revised 10Feb2020)

U-775

A-611

D-674

O-671

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGE\BRAKE COOLING PUMP GROUPS
5073 5068 5056		PS54231

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NOTE:	AVSpare’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 AVSpare.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS54231" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the 19Dec2019 (Revised 28Jan2020) Service Letter. Changes have been made to the Rework Procedure.

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TERMINATION DATE

31Dec2021

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	GT700153, 175-176, 182-183, 186, 188 RDR00128, 137, 144, 171, 212, 241-242, 245, 251-252, 263-264, 272, 288, 290, 301-302, 307, 328, 347, 354, 361-362, 371, 373, 375-378, 504, 506, 508-624, 2000-2050 TNM00160, 237, 239-240, 254, 256, 258, 260, 262, 264, 294, 298, 301, 322, 327, 362-363, 367-369, 381, 383, 388, 413, 432, 442, 448, 454-455, 475, 481, 487, 492, 495, 497-498, 514, 516, 518, 520, 532, 534-538, 540, 552, 566, 568, 577, 581, 588, 602, 612, 618, 623-624, 629-633, 636, 644, 676-677, 682, 693, 703-711, 719-721, 732-734, 751-752, 754-756, 770-775, 777, 791-793, 805-808, 818, 867, 878-879, 1010-1012, 1016, 1019-1022, 1032, 1035, 1040, 1045, 1049, 1051, 1060, 1068-1174, 2000-2009
777G OEM	T4Y00118, 131, 140, 150, 162, 181, 196, 200, 503-541, 2000-2001 T5A00118, 300-301

PARTS NEEDED

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Qty	Part Number	Description
1	3E6799	SEAL-O-RING
1	4J0520	SEAL-O-RING
1	4J0524	SEAL-O-RING
1	6J2680	SEAL-O-RING
1	2545009	GASKET
1	2933645	ELEMENT AS.-HYD
1	5738015	PUMP GP-GR B
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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 497-3512 Tandem Brake Cooling\Charge Pump Group with a new 573-8015 Tandem Brake Cooling\Charge Pump Group.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-6000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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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 tandem brake cooling\charge pump group.
- Some hardware and fittings to be reused.

1. Remove tandem pump group, suction tube, and discharge hoses. Refer to Image 1.2.1

Image1.2.1

2. Assemble the 3E-6799 O-ring Seal onto the new 573-8015 Gear Pump Group. Refer to Image 1.3.1

Image1.3.1

3. Connect the 573-8015 Gear Pump Group to the 485-9674 Gear Pump Group. Refer to Image 1.4.1

Image1.4.1

4. Reconnect the brake cooling pump discharge hose. Refer to Image 1.5.1.

Image1.5.1

5. Reconnect the brake charge pump discharge hose. Refer to Image 1.6.1.

Image1.6.1

6. Reconnect the tandem pump group suction line. Refer to Image 1.7.1

Image1.7.1

7. Ensure all connections are tight.

8. Replace the 293-3645 Brake Charge Filter Element Assembly.

9. Fill the hydraulic tank to the required level.

10. Prime new pump following the procedure in KENR9933.

11. After the truck has run for 5 minutes or more:
- apply the service brake and release 3 times
- release and engage the parking brake 3 times (move transmission shift lever from park to N)
- raise and lower the body twice

12. Take hoist/brake oil SOS sample and preform particle count.

13. If particle count is above specifications of ISO 18/15, kidney loop the system down to specification of ISO 18/15 or lower.

Kidney loop with truck running at low idle (ensure wheels are chocked) and while kidney looping, every 20 minutes:
- apply the service brake and release 3 times
- release and engage the parking brake 3 times (move transmission shift lever from park to N)
- raise and lower the body twice