PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLING SYSTEM ON CERTAIN 785C OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLING SYSTEM ON CERTAIN 785C OFF-HIGHWAY TRUCKS

Usage:

TEBE7539-00

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13Apr2018

V351

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE COOLING SYSTEM ON CERTAIN 785C OFF-HIGHWAY TRUCKS
1350 1380 1374		PS90871

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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.

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NOTE:	When reporting the repair, use "PS90871" 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.

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TERMINATION DATE

30Apr2019

PROBLEM

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The existing arrangement of cooling system can allow coolant overflowing from the jacket water shunt tank to the aftercooler shunt tank on certain 785C Off-Highway Trucks. This may compromise the lifetime of the engine (potential engine overheat).

AFFECTED PRODUCT

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Model	Identification Number
785C	APX02395-02404

PARTS NEEDED

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Qty	Part Number	Description
2	1P4579	FLANGE-SPLIT
1	2N0931	GASKET
1	4J0524	SEAL-O-RING
1	6V2235	CLIP
2	6V5066	SEAL-O-RING
1	6V6782	CLIP-TOP
1	6V6783	CLIP-BOTTOM
1	6V6809	SEAL-O-RING
2	6V8400	SEAL-O-RING-ORFS
1	6V9855	ADAPTER-ELBOW
1	7M8485	SEAL-O-RING-STOR
2	7X7729	WASHER-HARD
1	8T4196	BOLT-HEX HEAD
1	9S4181	PLUG-LD STOR
1	1030892	GROMMET
2	1100096	RING
1	1173050	ADAPTER-STR
73	1226907	HOSE-HYDRAULIC (73 inches)
1	1242082	COUPLING AS-PERM
1	1242125	COUPLING AS
2	2287094	SEAL-O-RING-ORFS
1	3445674	NUT-HEX
1	LOCTITE_243	LOCTITE 243 (10 ml) procure locally
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

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Rework cooling system using the attached Rework Procedure.

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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%
0-6000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-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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Remove all items in RED and use
(1) 7M-8485 ? o-ring
(1) 9S-9334 - plug (standard torque)

Image1.1.1

Hose As.
(1) 124-2082 - 45 coupling
(1810 mm) 122-6907 ? bulk hose 1810mm is the cut length of hose without couplings
(1) 124-2125 ? straight coupling

Image1.2.1

Use (4) 5P-2566 ? bolt (standard Torque)
and (4) 8t-4233 - washer
(2) 1P-4579 - 2pc flange
(1) 4J-0524 ? o-ring

Image1.3.1

(1) 6V-6782 - 2pc clamp top
(1) 6V-6783 - 2pc clamp bottom
(1) 103-0892 ? grommet
(1) 6V-2235 ? p clip
(1) 8T-4196 ? bolt
(2) 7X-7729 ? washer
(1) 344-5674 ? nut (standard torque)

Image1.4.1

(1) 117-3050 ? straight adapter (low Torque and apply thread sealant to NPTF thread
(1) 6V-9855 ? 90 adapter (standard torque and use backer wrench on 117-3050 when torquing)
(2) 228-7094 - o-ring

Image1.5.1

Before vs After the Rework

Image1.6.1

Image1.6.2

Note 1: Boss stands proud by 6-8mm. This can be machined down. Minimum wall thickness of hole is 10mm.

Image1.7.1

Note 2: The pump flange is in a perpendicular plane to the boss, and could be used to mount into a milling machine.

Image1.8.1

Note 3: Center new 1-5/64? (29mm) hole on boss, not on existing hole to achieve maximum wall thickness, tap to 1? NPT

Image1.9.1

Note 4: Apply Loctite 243 threadlocker to the threads of the pipe fitting. If this or local equivalent sealant is not available, use anaerobic sealant such as Loctite 5127 or 5188 on the pipe fitting threads. Torque fitting to 40N-m