PRODUCT SUPPORT PROGRAM FOR REPLACING THE PARK BRAKE PISTON OR SLEEVE ON CERTAIN R2900 AND R2900G LOAD HAUL DUMP MACHINES Caterpillar


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PRODUCT SUPPORT PROGRAM FOR REPLACING THE PARK BRAKE PISTON OR SLEEVE ON CERTAIN R2900 AND R2900G LOAD HAUL DUMP MACHINES [UEBE0453]
BRAKING SYSTEM
BRAKE GP
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PARK BRAKE PISTON OR SLEEVE ON CERTAIN R2900 AND R2900G LOAD HAUL DUMP MACHINES
UEBE0453-00

28May2020


U-350
A-295
D-334
O-330

 

After Failure Only

  
 Parts stock action needed 

PRODUCT SUPPORT PROGRAM FOR REPLACING THE PARK BRAKE PISTON OR SLEEVE ON CERTAIN R2900 AND R2900G LOAD HAUL DUMP MACHINES

4004 4061 4267 7555 4250 7750 4251
PS54353
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 "PS54353" 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.

NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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.


TERMINATION DATE

31May2022

PROBLEM

The existing 166-8174 Emergency Piston and 1V-6683 Sleeve may have non-conforming surface finish on certain R2900 and R2900G Load Haul Dump machines. If this condition exists, it may cause premature failure of the park brake piston seals, resulting in high axle oil level, and loss of park brake release function.

AFFECTED PRODUCT

Model Identification Number
R2900  ZLK00125, 127-132
R2900G  NLK00125-00255

PARTS NEEDED

Qty

Part Number Description
1 1V6683 SLEEVE
1 2A1162 GASKET
1 2R0098 SEAL-O-RING
1 3D2824 SEAL-O-RING-STOR
1 4D1577 SEAL-O RING
1 5B3265 GASKET-COPPER
1 6D0692 SEAL-O-RING
1 6F4855 SEAL-O RING
60 7K6058 BOLT-12 POINT HD
1 8S6251 SEAL-O RING
23 8T9399 BOLT-HEX HEAD
1 9G5323 SEAL GP-DUO CONE
10 0313185 BOLT-12 POINT HD
1 1155658 SEAL
1 1155659 SEAL
1 1668174 PISTON-EMERGENCY
3 3371943 SEAL-RECTANGULAR
1 3751155 SEAL-D-RING
1 3751156 SEAL-D-RING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

****Parts Stock ****

Inspect and all 166-8174 and 1V-6683 in dealer parts stock. Reject any parts with non-conforming surface finish in the specified areas.

 
 
****Affected Product****
In the event of a park brake piston seal failure, examine the finish of the seal running surfaces on the 166-8174 Emergency Piston and 1V-6683 Sleeve. If non-conforming parts exist, the failure qualifies for this Service Letter program.

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

 
 
****Affected Product****
Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-4000 hrs,
0-18 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 31.0-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.

Note: This is a random quality issue. A non-conforming part in one wheel position is not an indication that there will be a non-conforming part elsewhere on the machine. This Service Letter program is intended to cover repair of one wheel position.

Note: For repair of one wheel position, 13 Gal (49L) of TDTO SAE 50 Oil is allowed.



PARTS DISPOSITION

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

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



Rework Procedure


 
References:

R2900 LOAD HAUL DUMP MACHINES (NLK) - Refer to UENR7176, Disassembly and Assembly, "Final Drive and Brake - Disassemble & Assemble", for additional information.

R2900G LOAD HAUL DUMP MACHINES (ZLK) - Refer to M0099957, Disassembly and Assembly, "Final Drive and Brake - Disassemble & Assemble", for additional information.
 
1. Inspect the 166-8174 Piston and 1V-6683 Sleeve for a non-conforming surface finish. Refer to Image1.2.1.

A non-conforming surface finish will be visible with striations from the machining process on the seal running surface.

Run a fingernail along the surface finish, if machining cuts can be felt or the fingernail catches, the surface finish is non-conforming.

Alternatively, check the surface finish value. The finish should be 0.8 Ra on both parts.

Reject non-conforming parts. Replace with the same part numbers. Repeat inspection on replacement parts before installing.
Image1.2.1
 
1V-6683 Sleeve Inspection Detail:

Section (A) is 22mm (0.85in). It will interface with the seal and is the area of concern. It must have a 0.8 surface finish, and a fingernail should not catch.

Section (B) is 19mm (0.75in). It does not interface with the seal. This surface will have an F surface finish, and a fingernail may catch. This is NOT cause for rejection.

Refer to Image1.3.1.
Image1.3.1
 
166-8174 Piston Inspection Detail:

Sections (C) will interface with the seals and are areas of concern. They must have a 0.8 surface finish, and a fingernail should not catch. Refer to Image1.4.1.
Image1.4.1
 
 

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