A Directional Shift Management System Needs To Be Installed On Certain 768C Tractors; 769C, 771C, 773B, And 775B Trucks; And OEM Power Modules Caterpillar

A Directional Shift Management System Needs To Be Installed On Certain 768C Tractors; 769C, 771C, 773B, And 775B Trucks; And OEM Power Modules

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 must be administered as soon as possible. When reporting the repair, use "PI3654" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T " as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3654" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and " Z" as the SIMS Description Code.

Completion Date

March 31, 1994

Termination Date

September 30, 1994

Problem

A directional shift management system needs to be installed on certain 768C Tractors; 769C, 771C, 773B, and 775B Trucks; and OEM Power Modules to reduce the engine rpm before gear engagement takes place.

Affected Product
Model & Identification Number

Group 1

768C (02X371)

769C (01X6001, 01X6002, 01X6004-6022, 01X6024-6139, 01X6141-6180, 01X6182-6188, 01X6191, 01X6197, 01X6202, 01X6203, 01X6206-6210, 01X6212-6215, 01X6222-6228, 01X6231, 01X6233-6235, 01X6238, 01X6254)

771C (3BJ72, 3BJ74-77, 3BJ80-87)

OEM Power Modules (05A10030-10032, 05A10034, 05A10137, 05A10149, 05A10054)

Group 2

773B (63W03733-3789, 63W3791-3792, 63W3796-3808, 63W3810-3811, 63W3814-3817, 63W3819-3824, 63W3827-3830, 63W3832, 63W3835, 63W3837, 63W3839-3858, 63W3861-3864, 63W3866-3867, 63W3870-3872, 63W3877, 63W3904, 63W3906-3907, 63W3910-3911, 63W3913, 63W3925-3926, 63W3928-3931)

775B (7XJ76-89, 7XJ94-119)

Parts Needed

Dealers will need to order parts for this Program.

Group 1

2 - 5B2638 Bolt

1 - 6D1891 Fitting

1 - 6D9718 Hose Assembly

2 - 3J1907 Seal

1 - 5P7982 Elbow

4 - 8T4896 Washer

2 - 8T9101 Bolt

1 - 1013431 Valve Group

1 - 1050957 Bracket Assembly

Group 2

2 - 2B0941 Spacer

2 - 6D1891 Fitting

2 - 3J1907 Seal

1 - 4S7530 Hose Assembly

1 - 4S7560 Hose Assembly

4 - 8T4896 Washer

2 - 6V8801 Nut

2 - 7X0291 Bolt

1 - 1013431 Valve Group

Action Required

See the attached procedure.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

Groups 1 And 2

NOTE: This is a 2-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.

Parts Disposition

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

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

Group 1 - 768C, 769C, 771C And OEM Power Modules

1. Disconnect the 6D4044 Hose from the governor slave valve. See Illustration 1.

2. Remove the two 5B9603 Bolts and 5M2894 Washers from the oil fill tube support. Install the 105-0957 Bracket Assembly using two 5B2638 Bolts and two 8T4896 Washers where the support bolts were removed. See Illustration 2.

3. Install a 5P7982 Elbow and a 3J1907 Seal in the port in the block opposite the breather. Install a 6D1891 Connector and a 3J1907 Seal in the port opposite the solenoid. See Illustration 3.

4. Install the 101-3431 Valve Group on the 105-0957 Bracket Assembly using two 8T9101 Bolts and two 8T4896 Washers. See Illustration 4.

5. Connect the 6D4044 Hose removed from the governor slave valve to the 6D1891 Connector. Connect the 6D9718 Hose to the 5P7982 Elbow and to the elbow on the governor slave valve. See Illustration 5.

6. Connect the harness on the solenoid valve to the engine wiring harness and secure in Sure-Seal Clip. See Illustration 6.

7. Test the system to verify proper operation:

A) Elevate idle with foot throttle to 1200 RPM in neutral with parking brake off.

B) Place your foot on brake pedal to hold the truck and place the cane in 1st gear. Listen for RPM drop off prior to the truck engaging in gear.

Illustration 1

Illustration 2

Illustration 3

Illustration 4

Illustration 5

Illustration 6

Group 2 - 773B And 775B

1. Drill two 10.5 mm holes in the 7N6268 Bracket Assembly as shown in Illustration 7.

2. Assemble two 3J1907 Seals to two 6D1891 Connectors. Assemble the two 6D1891 Connectors to the 101-3441 Valve Group. See Illustration 8.

3. Assemble the 101-3441 Valve Group to the 7N6268 Bracket using two 7X0291 Bolts, four 8T4896 Washers, two 2B0941 Spacers, and two 6V8801 Nuts. See Illustration 9.

4. Disconnect the 4S7527 Hose from the cab and the 6G3641 Slave Valve. Remove two 6D3479 Clips and hardware. Remove the 4S7527 Hose. The 4S7527 Hose will not be reused. See Illustration 10.

5. Connect the 4S7560 Hose to the elbow on the cab and to the bottom fitting on the 101-3431 Valve Group. Secure the 4S7560 Hose using the two 6D3479 Clips and hardware removed in Step 4. See Illustration 11.

6. Connect the 4S7530 Hose to the connector assembled to the side of the 101-3431 Valve Group and to the elbow on the 6G3641 Slave Valve where the 4S7560 Hose was removed. See Illustration 12.

7. Connect the harness on the valve to the engine wiring harness and secure it in the Sure Seal Clip. See Illustration 13.

8. Test the system to verify proper operation:

A) Elevate idle with foot throttle to 1200 RPM in neutral with parking brake off.

B) Place your foot on brake pedal to hold the truck and place the cane in 1st gear. Listen for RPM drop off prior to the truck engaging in gear.

Illustration 7