Usage:
NOTE: This Program must be administered as soon as possible.When reporting the repair, use "PI30012" as the Part number and "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 "PI30012" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
NOTE: Some of the Affected Product fall into more than one group. Do all applicable portions of this Service Letter at the same time. Also, when applicable, this program should be done in conjunction with the April 19, 2000 Service Letter-PI30006 "Service Brake Slack Adjusters Need To Be Replaced On Certain D350E II And D400E II Articulated Trucks."
Completion Date
October 31, 2000Termination Date
April 30, 2001Problem
Group 1
New OMM'S are required to be installed in certain D350E II and D400E II Articulated Trucks. The original OMM'S supplied have mistakes in certain areas of the maintenance sections.
Group 2
Changes have been made to the park brake control logic for certain D350E II and D400E II Articulated Trucks. Changes prevent potential park brake damage during loading when the park brake is applied. A new transmission flash file also incorporates a change to the reverse gear selection and enables the top gear preselect and transmission hold functions to be a programmable parameter.
Affected Product
Model & Identification Number
Group 1
D350E II (2XW1-260)
D400E II (APF1-242, 8PS1-295, 8PS301-325, 8PS332-335, 8PS339-344, 8PS346-350, 8PS352-355, 8PS358-370, 8PS373-386, 8PS390-391, 8PS393-572)
Group 2
D350E II (2XW1-293)
D400E II (8PS1-295, 8PS301-325, 8PS332-335, 8PS339-344, 8PS346-350, 8PS352-355, 8PS358-370, 8PS373-386, 8PS390-391, 8PS393-607, APF1-251)
Parts Needed
Dealers will need to order parts for this Program.
Group 1
- 1 - 5P7958 SLEEVE-CA-SP
- See Chart Below OMM
Group 2
- 1 - 7F0880GASKET-ASBES
- 3 - 3J1907 SEAL-O-RING
- 3 - 4J5477 SEAL
- 1 - 3K0360 SEAL-O-RING
- 20 - 6L7008 STRAP-CABLE
- 1 - 2P1279 LOCKNUT-BULK
- 1 - 5P8874 ADAPTER
- 2 - 2T3019 CLIP
- 1 - 8T4121 WASHER-PLATE
- 1 - 8T4133 NUT
- 2 - 8T4183 BOLT
- 1 - 8T4185 BOLT
- 4 - 8T4223 WASHER-PLATE
- 2 - 8T4244 NUT
- 2 - 6U0455 STRAP
- 1 - 6V2455 SENSOR-AS-SP
- 1 - 6V8641 CONNECTOR
- 1 - 7X2444 TEE-SWIVEL
- 1 - 7X7945 ADAPTER
- 1 - 1283166 SWITCH-AS-PR
- 1 - 1482739 LINING-KIT-B
- 1 - 1863111 HARNESS-AS.-
- 1 - 1864753 PLATE-BULKHE
- 1 - 1864754 HOSE-AS.
- 1 - 1890069 HARNESS
- 1 - 1890070 HARNESS
- 3 - 3J1907 SEAL-O-RING
Action Required
Group 1
Select the correct language Operation and Maintenance Manual for the area the truck is operating. See the chart in the Parts Needed section.
Ensure that the manual supplied is the correct revision level from the list attached or higher if revised after the date of this service letter.
Remove the original OMM from the compartment behind the operators seat. Cut the lanyard close to the book. Destroy the original OMM that was removed from the truck.
Attach the OMM to the seat in the same manner as the original.
Use the new sleeve provided and deform the sleeve to provide a permanent joint.
Group 2
See the attached Group 2 Rework Procedure For Park Brake Logic.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
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-Group 2Rework Procedure)
Copy Of Owner Notification For U.S. And Canadian Owners
Group 2 Rework Procedure
Rework Procedure For Park Brake Logic
Machine Preparation:
1. Park the truck on level ground.
2. Chock the wheels to prevent movement of the truck when the park brake is released. Install the dump body prop.
Procedure:
Change Park Brake pads.
1. Start the engine and release the parking brake by depressing the button in the cab. The rod on the park brake actuator will be fully extended.
2. Manually increase the clearance of the parking brake slack adjuster by turning the adjusting screw (2) in the slack adjuster counter clockwise approx. 4 full turns.
3. Apply the park brake and stop the engine.
4. Loosen the 4 bolts on the right side of the park brake mounting (4) and remove the slide block.
5. Remove the park brake pads and install new pads. (if the pads that were removed were worn, the slack adjuster adjusting screw may require turning an additional amount counter clockwise to allow the installation of the new pads)
6. Re-install the slide block and 4 mounting bolts. Torque the bolts to 240 N·m (177 LB Ft)
7. Turn adjusting screw (2) clockwise until the park brake pads contact the park brake disc.
8. Start the engine.
9. Engage and disengage the parking brake control 25 to 30 times. Allowing 10 seconds between cycles. The park brake slack adjuster will automatically adjust the clearance of the park brake pads.
10. When step 9 has been carried out, leave the park brake control in the disengaged position and check the park brake pad clearance.
11. Push the spring brake actuator forward towards the front of the truck.
12. Use a feeler gauge and measure the distance between the brake disc and the front brake pad. At the point shown between the two arrows.
13. The measured distance (A) should be 0.7 to 1.1 mm (0.027 to 0.043 inch)
14. Engage the parking brake and stop the engine.
NOTE: The park brake pads and adjustment should be carried out prior to the pressure switch, harnesses and transmission flash file being installed.
Install pressure switch and harness.
1. Relieve pressure in the brake cooling and steering tanks by removing the tank filler caps.
2. Remove pressure test point from the ASBS valve front brake supply line and install 148-8325 Connector. Retain the test point to re-install in a different position.
3. Install all parts listed in locations as shown in the Illustrations.
4. Install single wires into the transmission ECM Connectors in pin numbers shown in Illustrations.
5. Connect the 3 pin Deutsch connector from the 186-3111 harness to the steering pressure switch connector in the existing tractor harness. This harness and connector are located above the body hoist valve in the right hand module of the tractor.
On later trucks this connector is a blank connector in the original harness (Note D on print).
On early D400E II trucks (8PS00001 to 000276) this connector is connected to a steer pressure sensor. Disconnect this sensor and leave it disconnected, it is not required.
On Ejector trucks (APF00001 - up) equipped with the 3Z5872 automatic blade control system there is also an additional harness attached to this connector. In this case, remove the wire (orange) from the automatic blade control harness and install this wire into the new harness (186-3111) in location "A" in the three pin Deutsch connector.
Connector
6. Install 6V2455 Sensor Gp-Speed and 7F0880 Gasket into the flywheel housing in the port on the left hand pump drive mounting. (remove plug 26 to install) Sensor should be screwed in until the end touches the internal gear and then turned back turn to provide running clearance.
Tighten check nut to 25 N·m.
Install New Transmission Flash File.
1. Obtain Flash File software part number 185-5356 from either the Caterpillar Mailbox System, the SIS Web System, or the SIS FLASH FILE CD.
NOTE: The SIS Flash File CD may take up to two months to receive the most up to date files. The mailbox and SIS Web systems always have the latest software.
2. Flash program the Transmission ECM with the 185-5356 flash file, using Electronic Technician (ET) and a 7X1701 Communication Adapter.
3. Test the truck for correct operation, as described below.
Changes to Park Brake logic.
With the introduction of the pressure switch and the new harness the logic on the park brake operation has changed.
Previously when the engine was running and the park brake control was in the engaged position the front axle service brakes and the drive line parking brake were both engaged and holding the truck. When the engine was stopped, only the park brake was engaged.
With the new logic, when the engine is running the front axle service brakes are applied and the drive line park brake is disengaged. When the engine is stopped the drive line park brake applies and the front axle service brakes are disengaged.
To test the park brake function. At the end of the rework place the empty truck on a 15% grade. Apply the park brake and stop the engine. The truck should hold in that position. If any movement is noted, recheck all adjustments and that the wiring has been installed correctly.