PRODUCT SUPPORT PROGRAM FOR REPLACING THE CUSHION HITCH HARNESS ON CERTAIN 657G WHEEL TRACTOR SCRAPERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CUSHION HITCH HARNESS ON CERTAIN 657G WHEEL TRACTOR SCRAPERS

Usage:

REBE6167-00

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17Aug2010

U-329

D-283

O-286

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Before/After Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CUSHION HITCH HARNESS ON CERTAIN 657G WHEEL TRACTOR SCRAPERS
1408		PS43144

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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 "PS43144" 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:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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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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TERMINATION DATE

31Aug2012

PROBLEM

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The existing harness can fail or break on certain 657G Wheel Tractor Scrapers. If the existing harness fails, it can result in loss of the cushion hitch function.

AFFECTED PRODUCT

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Model	Identification Number
657G	A4G00100 W1B00101-00102, 104-123, 125-147 W1C00201-00285
657G OEM	DXG00100-00101 GRS00100
CIPI	0EM01920

PARTS NEEDED

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Qty	Part Number	Description
1	4L6454	BOLT
1	4P7429	CLIP-LADDER
2	4S1962	CLIP
3	5P9297	CLIP
3	6D4246	CLIP-LOOP
1	6V8801	NUT
2	7K1181	STRAP-CABLE
2	8T4896	WASHER-HARD
1	9L1775	BRACKET
2	1774562	GROMMET
3	1783620	STRAP-DUAL CLAMP
1	3571156	HARNESS AS-C/H
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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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****Parts Stock ****

Remove all 307-0232 harness from dealer parts stock.

****Affected Product****

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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Rework Procedure

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Refer to the Service Manual if/as necessary.

1) Move machine to a safe area and secure.
2) Disconnect cushion hitch harness from transmission harness on top of case. Remove clips from transmission cooler tube. These clips will not be reused.
3) Remove cushion hitch harness, 227-4942/307-0232, from side of hitch. The harness and clips will not be reused. Remove the double clips from cushion hitch drain hose and harness. These double clips will not be reused. The bolts will be reused with the new parts.
4) Lay out harness (357-1156) along side of hitch. Connect harness to cushion hitch valve. Secure harness to cushion hitch valve mounting plate with 1 clip (5P-9297). Transfer arc suppressor from old harness to new harness and tie back with 1 tie-strap (7K-1181).
5) Secure harness at green tape with 1 clip (4S-1962) and 1 Grommet (177-4562) along with drain hose to existing bracket on hydraulic return tube. Reuse the nut and washers.
6) Secure harness to side of hitch with 1 bracket (9L-1775), 1 bolt (4L-6454), 2 washers (8T-4896), 1 nut (6V-8801), 1 grommet (177-4562), and 1 clip (4S-1962). Secure cushion hitch drain hose at same location with 1 clip (6D-4246). NOTE: The clip on the harness should be located to cover green tape.
Image 1.1.1
7) Route harness under hydraulic tubes and connect hitch harness to transmission harness on top of case.
8) Secure harness to transmission cooler tube with 1 tie strap (178-3620).
Image 1.1.2
9) Add 1 ladder clip (4P-7429) to outside lower corner of steering oil return tube. Secure harness to ladder clip with 1 strap (7K-1181).
Image 1.1.3
Image 1.1.4
10) Clip harness with 1 clip (5P-9297) and cushion hitch drain hose with 1 clip (6D-4246) to side of hitch at previous clipping points in two locations.
Image 1.1.5
11) Secure harness and cushion hitch drain hose together with 1 dual-strap (178-3620) in two locations:
... a) between two lower clipping points on side of hitch
... b) between top clip point on side of hitch and valve bracket clipping point.
12) Start machine and test cushion hitch for proper operation.
13) Return machine to service.