PRODUCT SUPPORT PROGRAM FOR REPLACING 1400212 BRAKE VALVE FOR THE SERVICE BRAKE VALVE ON CERTAIN 785C, 789C, AND 789D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING 1400212 BRAKE VALVE FOR THE SERVICE BRAKE VALVE ON CERTAIN 785C, 789C, AND 789D OFF-HIGHWAY TRUCKS

Usage:

TEBE4562-01

Show/hide table

01Jun2016

(Revised 15Jun2016)

J183
J189
J19D
J201
J210
J211
J217
J218
J21T
J248
J361
J363

Show/hide table

Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING 1400212 BRAKE VALVE FOR THE SERVICE BRAKE VALVE ON CERTAIN 785C, 789C, AND 789D OFF-HIGHWAY TRUCKS
5506 3123 4282 4265		PS90602

Show/hide table

NOTE:

Caterpillar’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 Caterpillar.

NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

Show/hide table

NOTE:	When reporting the repair, use "PS90602" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 01Jun2016 Service Letter. Changes have been made to the Affected Product.

Show/hide table

TERMINATION DATE

30Jun2018

PROBLEM

Show/hide table

The 2044270 Valve Group (Air Control Service Brake) can leak air through the 0549012 Cartridge on certain 785C, 789C, and 789D Off-Highway Trucks. The leaks drain air from the reservoir when the machine is parked for a long period of time. This makes it difficult to start the trucks equipped with an air starting motor.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
785C	APX00168-00175, 195-198, 399-401, 405, 407-413, 422-423, 432-434, 440-442, 488-493, 497-502, 517-519, 528, 532-535, 542-546, 576-580, 585-587, 590-591, 734-737, 966-967, 977, 979, 981-982, 986, 997, 1006, 1009-1014, 1270-1272, 1275-1286, 1385-1386, 1388-1395, 1399, 1408-1413, 1415-1417, 1419, 1421-1422, 1424, 1429, 1434, 1436-1438, 1445-1447, 1472, 1474, 1476, 1478, 1480, 1482, 1484, 1486, 1522-1524, 1526-1528, 1536, 1706-1714, 1719-1721, 1725-1731, 1735, 1738-1744, 1746-1747, 1764-1765, 1769-1775, 1782-1787, 1798, 1808-1810, 1822-1824, 1837-1841, 1864-1865, 1872-1874, 1880-1884, 1888-1892, 1909-1911, 1916, 1924, 1930-1946, 1950-1958, 1962-1970, 1974-1978, 1983-1987, 1990-1993, 2001-2015, 2058-2059, 2064, 2067-2073, 2075-2078, 2085, 2093-2097, 2103-2104, 2108, 2111-2112, 2126-2130, 2138-2142, 2157-2161, 2176-2180
789C	2BW00633-00634, 637-638, 641, 643-644, 648-656, 702-703, 710-711, 739, 842-845, 851-853, 1036-1038, 1499, 1507, 1509, 1520-1521, 1533, 1539, 1547-1548, 1701-1702, 1717-1718, 1803-1807, 1848-1852, 1888-1892, 1916-1920, 1926-1930, 1947-1951, 1965-1969, 1979-1983, 2003-2007, 2023-2026, 2028, 2047-2048, 2050-2052, 2077-2080
789D	SPD00182-00183, 191-192, 196, 211, 213, 215, 217-218, 238, 240, 242, 244-245, 269, 274-275, 278-279, 299, 301, 303, 305, 322, 331, 340-343, 379, 381, 383-384, 386, 404, 408

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
3	3B4505	LOCKWASHER
4	3J5389	PLUG-NPTF
2	3S8666	ELBOW-EXT PIPE
3	4M6425	BOLT
2	5M6213	PLUG-NPTF
3	8T4224	WASHER-HARD
3	8T9043	BOLT
1	9C8027	TREADLE AS
1	1393324	PLATE AS (as needed)
1	1400212	VALVE GP-BRAKE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

Show/hide table

Refer to the attached Rework Procedure to replace 1400212 Brake Valve.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-100000 hrs, 0-192 mo	100.0%	0.0%	0.0%	100.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 3.0-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: A maximum of 10 numbers of 139-3324 Plates will be allowed per dealership for use as a swing plate to fabricate as per Images. NOTE: A maximum of $75 will be allowed per claim to rework the existing 8X8579 Plate to the 139-3323 Plate as shown in the Images.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

1.Assemble Treadle 9C8027 to Valve 1400212 using bolts 4M6425 and lock washer 3B4505 and assemble to 13-20N.m.Refer to Image 1.1.1

Image1.1.1

2.Assemble Plugs 3J5389 and 5M6213 to valve 1400212 to every port except those facing the front of the assembly as seen. Apply Loctite 542 or 545 to threads of plugs. Refer to Image 1.2.1

Image1.2.1

3.Remove Valve group 2471292 and associated mounting hardware highlighted in Red. Refer to Image 1.3.1

Image1.3.1

4.Remove valve group 2371292 associated mounting hardware and adapters highlighted in red. Refer to image4.This view from the bottom of the cab. Refer to Image 1.4.1

Image1.4.1

5.Refer to image1.5.1 to modify the plate 1393324 of the new valve assembly.

Image1.5.1

6.Refer to Image 1.6.1 for Current Plate cut out for 1393323. Refer to Image 6

Image1.6.1

Refer to Image 1.7.1 for Suggested modified Cut out for 1393323

Image1.7.1

8.Refer to image 1.8.1 to Assemble Valve group to Plate 1393324.
Assemble the new valve assembly shown in red arrow on the Image (Blue)to the plate assembly(Green) using 8T4224(Orange) and 8T9043(Orange)

Image1.8.1

9.Refer to Image 1.9.1
Assemble Elbows 3S8666(Purple) to valve assembly(Blue)shown in red arrow on the image. Reroute existing houses(4S7560 and 7D5998)to new fitting maintaining inlet and outlet similar to prior Valve. Ensure no rubs with surrounding components by using existing clips. Apply Loctite 542 or 545 to thread)

Image1.9.1

10.Refer to Image 1.10.1 to Assemble fitting and brake Liners to valve.
Assemble Elbows 3S8666(Purple) to valve assembly(Blue)shown in red arrow on the image. Reroute existing houses(4S7560 and 7D5998)to new fitting maintaining inlet and outlet similar to prior Valve. Ensure no rubs with surrounding components by using existing clips. Apply Loctite 542 or 545 to thread)