PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGING PUMP ON CERTAIN 773G AND 775G OFF HIGHWAY TRUCKS Caterpillar


`
PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGING PUMP ON CERTAIN 773G AND 775G OFF HIGHWAY TRUCKS [UEBE1241]
HYDRAULIC SYSTEM
PUMP GP
PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGING PUMP ON CERTAIN 773G AND 775G OFF HIGHWAY TRUCKS
UEBE1241-01

05Nov2020
(Revised 11Nov2020)


U-642
A-531
D-606
O-597

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BRAKE CHARGING PUMP ON CERTAIN 773G AND 775G OFF HIGHWAY TRUCKS

5073
PS54471
NOTE:

AVSpare’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 AVSpare.

NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS54471" as the Part Number and "7755" as the Group Number. Use "96" as the 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 AVSpare product analyst.

 
NOTE:

This Revised Service Letter replaces the 05Nov2020 Service Letter. Changes have been made to the Rework Procedure.


TERMINATION DATE

30Nov2022

PROBLEM

The brake charging pump on certain 773G and 775G Off-Highway Trucks may experience a lower than acceptable life in certain applications. Internal design improvements have been implemented in order to increase the robustness of the brake charge pump.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
773G  JWS00403-00471, 2000-2013
773G OEM  T5T00108
775G  MJS00609-00839, 2000-2109
775G OEM  T5F00104, 106, 2000-2002
*******Group  2*******
773G  MWH00423-00470, 2000-2003, 78001-78002
775G  RFM00968-01177, 2000-2030
775G OEM  T5W00113-00115, 2000-2001

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
51 5P1295 HOSE BK (51 cm)
12 1440367 CLAMP-BAND
1 2933645 ELEMENT AS.-HYD
1 5940986 PUMP GP-GR B
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.

*******Group 2*******
51 5P1295 HOSE BK (51 cm)
12 1440367 CLAMP-BAND
1 2933645 ELEMENT AS.-HYD
1 5940989 PUMP GP-GR A
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

If a brake charge pump failure is experienced or imminent, then the brake charge pump should be replaced. Requirements for appropriate issuance of the support program are as follows:

1. Repeated occurrence of E284 Low Brake Accumulator Pressure Events and extended (20+ seconds) of brake accumulator charging time after engine startup. (Full system diagnosis must be performed to correctly isolate the pump as the root cause).

2. Complete loss of brake charge pressure. (Full system diagnosis must be performed to correctly isolate the pump as the root cause).

In addition to the pump replacement, the three 6G-0609 (three 17cm sections of 5P-1295 bulk hose) Hose sections within the suction plumbing assembly should be replaced with new parts, including the 144-0367 Band Clamps.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-6000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs,
25-36 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 5.0-hour job for Group 1

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-6000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs,
25-36 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 5.0-hour job for Group 2



PARTS DISPOSITION

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


Rework Procedure


 
1. Drain the hydraulic tank of all the old oil.

2. Disconnect the suction and discharge lines from the brake charging pump. (Note: On HRC machines there will be 2 discharge hoses).

3. Unbolt the brake charging pump (2 bolts) from the rear of the hoist pump assembly and remove the brake charging pump from the machine.
 
4. Detach the suction tubing from the short hose couplings between the tank and the pump. (Location of coupling hoses shown in image 1.2.1).

5. Inspect the steel tube sections for signs of corrosion, pitting or damage. (Replace if required).

6. Verify the ends of the tubes where they seal inside of the hoses are clean, smooth and free from surface defects that could create lack of sealing.

7. Install new suction hoses and use new clamps.

8. Before tightening the clamps verify that the hoses are engaged onto the tubes an equal distance and that the tubes are in alignment with each other. If the tubes are not aligned please loosen the mounting hardware for the tube and manipulate into alignment. (Note: Image 1.2.3 shows improper hose alignment).

9. Install clamps with screws 180 degrees apart. (Shown in image 1.2.2).
Image1.2.1
Image1.2.2
Image1.2.3
 
10. Install new pump assembly. Reattach hoses using new sealing rings.
 
11. Refill hydraulic tank to the specified oil level in the tank gauge.

12. Pressurize the hydraulic tank with 55 kPa (8 psi) to 69 kPa (10 psi) of air pressure.

13. Connect a quick connect coupler (E) with open port or hose attached to the 329-5532 Tee As (quick disconnect fitting) on the control manifold (Brake Accumulator Charging Valve located behind the brake accumulators).
Image1.4.1
 
14. Enable the engine kill switch (fuel injection disable) located on the front bumper (or stairway) of the machine, for the engine's Engine Control Module (ECM) and crank the engine.
Note: Do not crank the engine more than 20 seconds at a time.

Note: Refer Operation and Maintenance Manual, M0110121, "773G and 775G Off-Highway Truck" , Engine Shutdown Switch.

15. Crank the engine until the oil appears with good flow from the port at the accumulator charging valve.

16. Remove quick connect coupler (E) and drain the hose. Re-energize the engine ECM and with the tank still pressurized start the engine and run for 5 minutes. Monitor the machine for any active brake accumulator pressure events.

17. After starting the engine, the brake charge indicator on the dashboard should go out shortly in around 10 to 15 seconds.

18. Remove the tank pressurization equipment and reconnect the vent line.

19. The machine can return to operation.
 
 

Information System:

PRODUCT SUPPORT PROGRAM FOR REPLACING THE MAGNETS ON THE MUD GUARD FOR THE DYNAMIC GAS BLENDING (DGB) LIQUID NATURAL GAS (LNG) TANK ON CERTAIN 785C OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER PUMP ON CERTAIN 797F OFF-HIGHWAY TRUCKS WITH HIGH ALTITUDE ARRANGEMENT
PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE FUEL FILTER ON CERTAIN 797F OFF-HIGHWAY TRUCKS ENGINES WITH HIGH ALTITUDE ARRANGEMENT
PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION ON CERTAIN 797, 797B, AND 797F OFF-HIGHWAY TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING 20R3317, 20R3318, 20R3320, 20R3321, 20R3324, 20R3328, AND 20R8517 REMAN VALVE ROCKER ARMS FROM DEALER PARTS STOCK
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 318-3721 HUMP HOSES FROM DEALER PARTS STOCK
PRODUCT SUPPORT PROGRAM FOR INSTALLING SOFTWARE ON CERTAIN 793F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REROUTING THE EXCITION LEADS ON CERTAIN GENERATORS USED ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPEED SENSOR ON CERTAIN COMPACTORS AND AP355F PAVERS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING 395-5455 AND 395-5456 HOSE ASSEMBLIES ON CERTAIN MH3037 MATERIAL HANDLERS
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING ALL 516-2725 DEF PUMPS FROM DEALER PARTS STOCK
PRODUCT SUPPORT PROGRAM FOR REPLACING THE SHIFT VALVE ON CERTAIN CP54B, CP56B, CS54B, CS56B, CS74B, AND CS78B VIBRATORY SOIL COMPACTORS
PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE COMPRESSOR LINE CLAMPS ON CERTAIN 797F OFF-HIGHWAY TRUCKS WITH 4X4 ENGINE SERIAL PREFIX
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 445-9753 EXHAUST BRACKET ON CERTAIN 794 AC AND 796 AC OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR INSPECTING THE CAMSHAFT ON CERTAIN 797F OFF-HIGHWAY TRUCKS, EQUIPPED WITH THE HIGH ALTITUDE ARRANGEMENT
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PRODUCT LINK RADIO ON CERTAIN CATERPILLAR PRODUCTS
PRODUCT SUPPORT PROGRAM FOR INSPECTING CONNECTING RODS AND POSSIBLY REPLACING A CYLINDER PACK ON CERTAIN 793F AND 794 OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW FRONT WHEEL ON CERTAIN 777G OFF-HIGHWAY TRUCKS AT REBUILD
PRODUCT SUPPORT PROGRAM FOR REPLACING THE MACHINE PIN PLATE ON CERTAIN 150 AND 160 MOTOR GRADERS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM CYLINDER, STICK CYLINDER, AND GRAPPLE CYLINDERS ON CERTAIN 559D AND 2384D KNUCKLE BOOM LOADERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE AND AFTERTREATMENT SOFTWARE ON CERTAIN 994K WHEEL LOADERS
PRODUCT SUPPORT PROGRAM FOR INSPECTING AND INSTALLING RADIO BRACKET FOR CAB PANEL ASSEMBLY ON CERTAIN 794 AC, 796 AC, AND 798 AC OFF-HIGHWAY TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 217-4193 AND 217-4195 COOLANT HOSES FROM DEALER PARTS STOCK
PRODUCT SUPPORT PROGRAM FOR REPLACING THE NRS COOLER ON ON CERTAIN 336F, 340F AND 352F EXCAVATORS, 725, 730 AND 735 ARTICULATED TRUCKS, 772G OFF-HIGHWAY TRUCKS, 826K LANDFILL COMPACTORS, 966, 972 AND 980 WHEEL LOADERS, D6T TRACK-TYPE TRACTORS, AND P