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Carta de Servicio
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN IMPROVED CHECK VALVE IN
THE TRACTION CONTROL SYSTEM (TCS) ON CERTAIN 797 AND 797B OFF-HIGHWAY
TRUCKS
Número de medio -SEBE9105-00 Fecha de publicación -10/03/2005 Fecha de actualización -16/03/2005
CONFIDENTIAL
SEBE9105

March 10, 2005

U-81
A-61
D-68
O-70

Priority PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING

AN IMPROVED CHECK VALVE IN THE TRACTION
Parts stock action needed CONTROL SYSTEM (TCS) ON CERTAIN 797 AND 797B
OFF-HIGHWAY TRUCKS

4811 4294 PI30784

NOTE: This Program must be administered as soon

as possible. When reporting the repair, use
"PI30784" 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 "PI30784" as the Part Number, "7751"
as the Group Number, "96" as the Warranty Claim
Description Code, and "Z" as the SIMS Description

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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.

COMPLETION DATE TERMINATION DATE

September 30, 2005 March 31, 2006

PROBLEM
A new double-seated plug (check valve) has been released to replace
the existing check valve in the Traction Control System (TCS) on
certain 797 and 797B Off-Highway Trucks. This new check valve should
be installed during the next scheduled Preventative Maintenance
service for these trucks. The installation of the new 257-7440 Plug
As (Check Valve) eliminates the need to visually inspect the valve
every 500 hours. (as was instructed for the 254-0089 Plug As.)

NOTE: The 254-0089 Plug As (Check Valve) was

installed while performing the April 7, 2004
Service Letter - PI30643, "Product Improvement
Program For Installing An Improved TCS Check
Valve In Certain 797 and 797B Off-Highway Trucks.

AFFECTED PRODUCT

Model Identification Number

797 5YW1-277

797B JSM1-196

PARTS NEEDED
Dealers will need to order parts for this Program.

Quantity Part Number Description

1 2577440 PLUG AS

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NOTE: One 257-7440 Plug As (Check Valve)

will also be required for reworking each
169-1751 TCS Control Group that is in
dealer parts stock.

ACTION REQUIRED
***** Parts Stock *****

Part 1 - Plugs (Check Valves)

Remove all 254-0089 Plug As (Check Valve) from dealer parts stock.

Part 2 - TCS Control Groups

Note: One 257-7440 Plug As (Check Valve) will be

required for each 169-1751 TCS Control Group
reworked

Rework all 169-1751 TCS Control Groups in dealer parts stock by

removing the existing 254-0089 Plug (Check Valve) and installing a
new 257-7440 Plug (Check Valve). Refer to Steps 3 thru 6 in the
attached rework procedure for the Affected Product as necessary. Make
sure that the 257-7440 Plug Assembly (Check Valve) is tightened to a
torque of 45 N-m.

***** Affected Product *****

See the attached procedure.

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

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Part 1 - Plugs (Check Valves)

Submit one claim for all 254-0089 Plug Assemblies (Check Valves)
removed from dealer parts stock.

Part 2 - TCS Control Groups

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Submit one claim for all 169-1751 TCS Control Groups that were
reworked and returned to dealer parts stock.

One 257-7440 Plug and one hour of labor will be allowed for each
control group that is reworked.

***** Affected Product *****

Caterpillar Dealer Suggested Customer Suggested

Labor
Parts Labor Hrs. Parts Labor Hrs. Parts
Hrs.

100% 2 0 0 0 0

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
***** Parts Stock *****

Handle the parts in accordance with your Warranty Bulletin on

warranty parts handling.

***** Affected Product *****

Handle the parts in accordance with your Warranty Bulletin on

warranty parts handling.

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
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

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PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN IMPROVED

CHECK VALVE IN THE TRACTION CONTROL SYSTEM (TCS) ON CERTAIN 797 AND
797B OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 797 AND 797B OFF-HIGHWAY TRUCKS

Dear Caterpillar Product Owner:

A new double-seated plug (check valve) has been released to replace

the existing check valve in the Traction Control System (TCS) on the
products listed below. This new check valve should be installed
during the next scheduled Preventative Maintenance service for these
trucks. The installation of the new 257-7440 Plug As (Check Valve)
eliminates the need to visually inspect the valve every 500 hours.

Contact your local Caterpillar dealer immediately to schedule this

service. The dealer will advise you of the time required to complete
this service. Please refer the dealer to their Service Letter dated
March 10, 2005 when scheduling this service. You will not be charged
for the service performed.

We regret the inconvenience this may cause you, but urge you to have
this service performed as soon as possible to prevent unscheduled
downtime.

Caterpillar Inc.

Identification #(s)

Attached to March 10, 2005 Service Letter

REWORK PROCEDURE
Procedure for replacing the plug assembly in the 169-1751 TCS
traction control valve on the 797 Off-Highway Truck at the first 500-
hour inspection.

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Figure 1: Location of the 169-1751 TCS Valve on the 797 Truck

Figure 2: Close-up View of the TCS Valve

1. Restrain the truck from moving and secure the body in the raised
position by connecting the body retaining cables.

2. Locate the 169-1751 TCS Valve. See Figures 1 & 2.

3. Remove two 0S-1590 Bolts, two 5M-2894 Washers, the 172-6242 Cover
Assembly, the 172-6236 Retainer, the 8M-4436 Seals (qty 2), and the
6T-7532 Screen Assembly from the TCS valve (169-1751). Refer to

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Figure 3 for a cross-section of the TCS valve.

4. Remove the 254-0089 Plug Assembly.

5. Install the 257-7440 Plug Assembly and tighten to a torque of 45

N-m.

6. Re-assemble the two 0S-1590 Bolts, two 5M-2894 Washers, the 172-
6242 Cover Assembly, the 172-6236 Retainer, 8M-4436 Seals (seals can
be reused if in good condition - qty 2), and clean 6T-7532 Screen
Assembly to the TCS valve.

Figure 3: Cross Section View of TCS Valve

Copyright 1993 - 2005 Caterpillar Inc. Tue Apr 5 17:57:06 UTC-0400 2005
Todos los derechos reservados.
Red privada para licenciados del SIS.

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