PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HYDRAULIC TANK COVER ON CERTAIN 777F AND 777F OEM OFF HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HYDRAULIC TANK COVER ON CERTAIN 777F AND 777F OEM OFF HIGHWAY TRUCKS

Usage:

REBE4309-00

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05Nov2008

U-557

A-462

D-475

O-512

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HYDRAULIC TANK COVER ON CERTAIN 777F AND 777F OEM OFF HIGHWAY TRUCKS
5056 3177		PS42822

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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 "PS42822" 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.

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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 Caterpillar product analyst.

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TERMINATION DATE

30Nov2010

PROBLEM

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The existing sight gage on certain 777F Off Highway Trucks was positioned incorrectly. A new tank design (Type 2) was introduced with the sight gauge in the correct location. In order to fill the original tank (Type 1) properly, the machine must be allowed to cool down to ambient temperature and then filled to the hot level indicator instead of the cold level indicator. The hydraulic system will function properly with a Type 1 tank filled using this procedure.

Type 1 and Type 2 tanks can be differentiated by comparing sight gauge locations. Sight gauges have been aligned on the Type 2 tank to as illustrated in Image 1 and Image 2.

AFFECTED PRODUCT

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Model	Identification Number
777F	JRP00277-00757, 759-783, 785-945, 947-959, 962, 964-970, 972-976, 978-1160, 1162-1547
777F OEM	JXP00100-00101 WTK00105-00117

PARTS NEEDED

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Qty	Part Number	Description
1	4J8251	GROMMET
1	4T2567	GASKET
6	5H6005	SEAL-O RING
1	6J1080	GROMMET
1	3322913	COVER
1	S_B_7790	OPERATION AND MAINTENANCE MANUAL (SEE NOTE BELOW)
NOTE: When ordering Operation and Maintenance Manual S_B_7790, verify that it is version -06 or later. In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% 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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A new cover has been released with a repositioned sight gauge. The existing tank cover should be removed and replaced with the new tank cover with the sight gauge correctly positioned.

Install a new Operation and Maintenance Manual containing the correct maintenance requirements for the Type 2 tank in the customers machine.

This is the Permanent Corrective Action for this issue. This service letter program supercedes the previous Interim Corrective Action service letter program, PI31471.

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Image1

Image2

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%
0-8000 hrs, 0-36 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

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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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The rework procedure should be done during a normal hydraulic system oil change interval as descrided in the Operation and Maintenance Manual, "Maintenance Interval Schedule". The work should be done in a clean environment to minimize contamination.

1. Drain the hydraulic tank as described in the Operation and Maintenance Manual, "Hoist, Torque Converter and Brake Tank Oil - Change".
2. Remove the hydraulic tank cover.
3. Clean the mating surface on the tank to remove all gasket material and burrs on the machined surface. Use a 6V-0185 or similar Reconditioning Disc to clean these surfaces.
4. Remove the sight gauge and retainer from the old tank cover and reinstall on the new tank cover using new seals and grommets.
5. Inspect the bottom of the hydraulic tank for debris and clean as needed.
6. Inspect, clean, and reinstall the suction screens.
7. Install the new 332-2913 Cover using a new 4T-2567 Gasket.
8. Refill the hydraulic tank as described in the Operation and Maintenance Manual, "Hoist, Torque Converter and Brake Tank Oil - Change".
9. Provide the customer with a new copy of the Operation and Maintenance Manual, and review the tank oil fill procedures containing the correct maintenance requirements for the Type 2 tank. Install the new Operation and Maintenance Manual in the customers machine.