PRODUCT SUPPORT PROGRAM FOR REWORKING THE TORQUE CONVERTERS IN CERTAIN D6R SERIES II, D6R XL SERIES II, D6R LGP SERIES II, D6R XW SERIES II, D7R SERIES II, D7R XR SERIES II, AND D7R LGP SERIES II TRACK-TYPE TRACTORS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REWORKING THE TORQUE CONVERTERS IN CERTAIN D6R SERIES II, D6R XL SERIES II, D6R LGP SERIES II, D6R XW SERIES II, D7R SERIES II, D7R XR SERIES II, AND D7R LGP SERIES II TRACK-TYPE TRACTORS
Usage:
REBE2492-01
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14Dec2007
(Revised 18Dec2007)
U-648
A-528
D-530
O-567
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Before/After
PRODUCT SUPPORT PROGRAM FOR REWORKING THE TORQUE CONVERTERS IN CERTAIN D6R SERIES II, D6R XL SERIES II, D6R LGP SERIES II, D6R XW SERIES II, D7R SERIES II, D7R XR SERIES II, AND D7R LGP SERIES II TRACK-TYPE TRACTORS
3101
PS42579
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NOTE:
This Program must be administered either before or after failure.
In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42579" as the Part Number
and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.
If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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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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NOTE:
This Revised Service Letter replaces the 14Dec2007 Service Letter. Changes have been made to Parts Needed
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TERMINATION DATE
31Dec2010
PROBLEM
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The 179-9579 Bearing in the torque converters of certain D6R II, D6R XL II, D6R LGP II, D6R XW II, D7R II, D7R XR II, and D7R LGP II Track-Type Tractors can fail prematurely resulting in damage to the torque converter and contamination of the power train oil system.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an inital 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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NOTE: A before failure repair can only be applied to machines with less than 2000 SMU.
There are separate procedures, parts required, and service claim allowances for before or after failure repair options.
Refer to the rework procedure for the correct action to be taken.
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SERVICE CLAIM ALLOWANCES
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-2000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs, 25-36 mo
67.0%
75.0%
0.0%
0.0%
25.0%
25.0%
4001-6000 hrs, 37-48 mo
33.3%
50.0%
0.0%
0.0%
50.0%
50.0%
6001-8000 hrs, 49-60 mo
6.0%
25.0%
0.0%
0.0%
75.0%
75.0%
NOTE: This is a 24.0-hour job for Group 1
Before failure can only be applied to machines under 2000 hours.
An additional 74 hours will be allowed for after failure repairs.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-2000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs, 25-36 mo
67.0%
75.0%
0.0%
0.0%
25.0%
25.0%
4001-6000 hrs, 37-48 mo
33.3%
50.0%
0.0%
0.0%
50.0%
50.0%
6001-8000 hrs, 49-60 mo
6.0%
25.0%
0.0%
0.0%
75.0%
75.0%
NOTE: This is a 24.0-hour job for Group 2
Before failure can only be applied to machines under 2000 hours.
An additional 74 hours will be allowed for after failure repairs.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-2000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs, 25-36 mo
66.0%
75.0%
0.0%
0.0%
25.0%
25.0%
4001-6000 hrs, 37-48 mo
33.3%
50.0%
0.0%
0.0%
50.0%
50.0%
6001-8000 hrs, 49-60 mo
6.0%
25.0%
0.0%
0.0%
75.0%
75.0%
NOTE: This is a 24.0-hour job for Group 3
Before failure can only be applied to machines under 2000 hours.
An additional 74 hours will be allowed for after failure repairs.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Before Failure Repair Procedure
Note: Before failure only applies to machines under 2000 hours.
Reference RENR4271 "Disassembly and Assembly for D6R Series II Track-Type Tractors Power Train" and RENR5626 "Disassembly and Assembly for D7R Series II Track-Type Tractors Power Train"
1. Remove the torque converter from the machine. 2. Remove the planetary carrier from the torque divider. 3. Remove the torque converter from the housing. 4. Remove the center shaft from the torque converter. 5. Remove the impeller assembly from the rotating housing. 6. Remove stator assembly from the impeller assembly. 7. Remove carrier assembly from the impeller. 8. Remove dowel retaining the outer race of the 179-9579 Bearing to the impeller. 9. Remove bearing retainer and bearing from the impeller 10. Check the clearance between the impeller and stator and the turbine and stator. 11. Install the 304-9651 Bearing into the new 1T-2070 Retainer. 12. Install the bearing and retainer into the impeller. 13. Install dowel between outer race of bearing and impeller. 14. Bolt bearing retainer to impeller. 15. Install seal ring and spring pins onto the 1T-2095 Carrier Assembly. 16. Install carrier into impeller assembly. 17. Install stator onto carrier assembly. 18. Install impeller onto rotating housing. 19. Reinstall torque converter shaft. 20. Reinstall the torque converter into housing. 21. Reinstall torque divider planetary. 22. Install the torque converter assembly into the machine.
After Failure Repair Procedure
Reference RENR4271 "Disassembly and Assembly for D6R Series II Track-Type Tractors Power Train" and RENR5626 "Disassembly and Assembly for D7R Series II Track-Type Tractors Power Train"
1. Perform work listed under before failure option replacing any other damaged components. 2. Begin cleaning power train oil system by cleaning all suction screens in the case, torque converter, and transmission. 3. Remove the power train oil cooler and flush the cooler lines. 4. Install Reman oil cooler core.
Note: Some of the earlier D6R Series II machine used a smaller 127-5537 Cooler core. Service Magazine SEPD0751 "A New Power Train Oil Cooler is Now Used on the D6R Series II Track-Type Tractors" addresses the change to the larger cooler listed in this service letter. If the machine has not been updated, use OR-8402 Cooler Core for the repair.
5. Remove final drives from the machine to inspect/clean the brake components. 6. Remove transmission for cleaning and inspecting. 7. Clean case sump and tubes. 8. Remove brake valve and clean inlet screens. 9. Reinstall final drives, transmission, and torque converter. 10. Replace power train oil filter. 11. Kidney loop the power train oil to cleanliness level of 16/13. Do not shift the transmission during the kidney looping process. 12. Replace the power train filters again. 13. Replace all 5 transmission modulating valves. 14. Calibrate the transmission modulating valves.
