PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LADDER HINGE HOUSING ON CERTAIN D11T TRACK-TYPE TRACTORS EQUIPPED WITH ACCESS LADDERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LADDER HINGE HOUSING ON CERTAIN D11T TRACK-TYPE TRACTORS EQUIPPED WITH ACCESS LADDERS

Usage:

REBE6291-00

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06Aug2010

U-303

A-234

D-259

O-262

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LADDER HINGE HOUSING ON CERTAIN D11T TRACK-TYPE TRACTORS EQUIPPED WITH ACCESS LADDERS
7254		PI31782

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31782" 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 "PI31782" as the Part Number, "7751" as the Group Number, "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, "7751" as the Group Number, "56" as the 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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COMPLETION DATE	TERMINATION DATE
28Feb2011	31Aug2011

PROBLEM

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The 258-9911 Housing can crack near the upper left and/or upper right bolt holes on certain D11T Track-Type Tractors. A new 357-7708 Housing has been designed to reduce stress near the bolt holes and extend service life.

AFFECTED PRODUCT

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Model	Identification Number
D11T	GEB00174, 179, 185-186, 224, 226, 228-229, 248, 260, 266, 269, 308, 336, 339-340, 346, 362, 369, 377, 397-398, 405, 430, 447, 449-451, 453-454, 457, 462-463, 466, 471-472, 483-484, 489, 492-496, 503-504, 506, 520, 527, 530, 532-535, 554-555, 561, 569-572, 575, 578-579, 581, 591-592, 595-599, 602-605, 608-609, 617, 619-622, 625-628, 632, 639, 641-643, 653-654
D11T CD	TPB00169-00170, 173-174, 177-183

PARTS NEEDED

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Qty	Part Number	Description
2	8T6868	BOLT (Used as Tooling During Assembly Process)
1	3633193	KIT-HOUSING SERV
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 ****

Rework all 258-9910 Hinge Assemblies that are in dealer parts stock. Refer to the attached Rework Procedure for the rework instructions. Once the hinge assembly has been reworked, the hinge assembly can be placed back in to dealer stock for future use.
NOTE: The new hinge housing will be marked with part number 357-7708. The old hinge housing was marked with part number 258-9911.

****Affected Product****

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To eliminate the possibility of hinge housing cracking, replace the
258-9911 Housing with a 357-7708 Housing per the Rework Procedure. The 357-7708 Housing is included in the 363-3193 Kit. While installing the reworked hinge assembly on the tractor, check for fender flatness and shim as required per the instructions referenced at the end of the Rework Procedure.
NOTE: The new hinge housing will be marked with part number 357-7708. The old hinge housing was marked with part number 258-9911.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

5.0 Hours Labor and one 3633193 Kit will be allowed for each hinge assembly from dealer parts stock that is reworked.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 8.0-hour job
NOTE: If there has been a previous repair, part age will apply. Retain a copy of the previous repair in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the Warranty claim.

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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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LADDER HINGE HOUSING ON CERTAIN D11T TRACK-TYPE TRACTORS EQUIPPED WITH ACCESS LADDERS

MODELS INVOLVED - D11T TRACK-TYPE TRACTORS

Dear Caterpillar Product Owner:

The 258-9911 Access Ladder Hinge Housing needs to be replaced with an improved 357-7708 Hinge Housing on products listed below. The existing housing can crack which renders the ladder system unfit for use. You will not be charged for the service performed.

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 06Aug2010 when scheduling this service.

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 06Aug2010 Service Letter

Rework Procedure

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Refer to the Service Manual if/as necessary.

A. Remove 258-9910 Hinge Assembly from tractor using the applicable steps from Special Instruction REHS4320.

B. Disassemble the 258-9910 Hinge Assembly per the following "DISASSEMBLY STEPS"

Note: The three parts shown in the following chart will not be reused.

Image1.2.1

Note: The following parts should be saved for reuse:

Image1.3.1

DISASSEMBLY STEPS

1. Remove plug (1) and the O-Ring seal. Drain the oil from the gear housing into a suitable container for storage or disposal.

Image1.4.1

2. Remove plate (2) and the gasket from the gear housing. Remove plug (3) from plate (2).

Image1.5.1

3. Remove couplings (4) from both sides of the gear housing. Remove plugs (5) from the couplings. Leave the O-ring seals on the plugs (5).

Image1.6.1

4. Inspect the lip seals (6) while they are on the couplings (4). If the seals are not damaged, leave on the coupling (4) for reuse.

Image1.7.1

5. Remove hydraulic motor (7) and the gasket. Do not remove coupling housing (8). Loosely install bolts into coupling housing (8) for storage.

Image1.8.1

6. Remove caps (9) and shims (10) from both sides of the gear housing.

Image1.9.1

Image1.9.2

7. Inspect O-Ring seals (11) on the caps (9). If the seals are not damaged, leave on the caps (9) for reuse.

Image1.10.1

8. Inspect lip seals (12) and caps (9) for damage. If they are not damaged, do not remove from caps (9). Note: If a new lip seal (12) needs to be installed, the face of lip seal (12) should be flush with the face of the cap (9).

Image1.11.1

9. Remove the shaft (14) and thrust bearings (15). Remove gear (16) through the large opening in the gear housing.

Image1.12.1

Image1.12.2

10. Remove coupling housing (8) and shims (17).

Image1.13.1

Image1.13.2

11. Remove O-ring seal (18) from coupling housing (8).

Image1.14.1

12. Remove shaft (20) from the gear housing. Inspect the bearing cones (22). If the bearing cones are not damaged, leave them on the shaft (20).

Image1.15.1

Image1.15.2

C. Assemble the parts to make a rebuilt 359-6795 Hinge Assembly per the following "ASSEMBLY STEPS".

ASSEMBLY STEPS

NOTE: The 110-0013 Cup Bearing has already been pressed in the 357-7708 Housing that was provided in the 363-1393 Kit.

Image1.17.1

1. Install shaft (20) with coupling (21) and bearing cones (22) into the gear housing. Make sure the end of the shaft (20) with the coupling (21) protrudes from the gear housing.

Image1.18.1

Image1.18.2

2. Use Tooling - 8T-6868 Bolts (A) to install coupling housing (8) and shim pack (17) over the end of the shaft (20). NOTE: Do not install the O-Ring seal at this time. Adjust the thickness of the shims (17) so that there is no gap between shims (17), the gear housing, and coupling housing (8). Tighten tooling - 8T-6868 Bolts (A).

Image1.19.1

Image1.19.2

3. Rotate shaft (20) by at least 5 full rotations in order to ensure that the bearing cones are fully seated in the bearing cups.

4. Measure end play of shaft (20). Add or remove shims (17) in order to achieve an end play of 0.0254 to 0.1270 mm (0.001 to 0.005 inch). Ensure that shaft (20) spins freely.

Image1.20.1

5. Install gear (16) through the large opening in the gear housing. Install shaft (14) through gear (16). Install thrust bearings (15) onto each end of shaft (14).

Image1.21.1

Image1.21.2

6. Apply a thin coat of oil to the outside diameter of caps (9). Position caps (9) with O-Ring seals (11) over the shaft (14) and onto both sides of the gear housing. Install shims (10) between caps (9) and the gear housing.

Image1.22.1

Image1.22.2

Image1.22.3

7. Tighten the bolts on one of caps (9). Do not over tighten the bolts. Install the bolts onto the remaining cap (9).

8. Use a dial indicator to measure the end play of the shaft (14). Adjust the end play by adding or removing the same number of shims (10) from each side. Establish the end play between 0.05 to 0.15mm (0.002 to 0.006 inch).

9. Remove coupling housing (8) and O-ring (18) from the gear housing. Install O-Ring seal (18) onto the coupling housing (8). Discard Tooling - 8T-6868 Bolts (A).

Image1.24.1

10. Install coupling housing (8) with O-ring seal, the gasket, and hydraulic motor (7) using existing 3E-8007 Bolts (M12x1.75)

Image1.25.1

11. Install plugs (5) and the O-ring seals onto couplings (4). Install lip seal (6), coupling (4), and plug (5) assemblies onto both sides of the gear housing. Make sure the splines of the shaft are engaged with the splines on couplings (4).

Image1.26.1

Image1.26.2

12. Install plate (2) and the gasket onto the gear housing. Do not install plug (3) into the plate (2) at this time.

13. Install plug (1) and the O-ring seal into the gear housing. Position the gear housing into the orientation of final installation onto the machine. Fill the oil into the gear housing through the hole in plate (2). Fill the oil into the gear housing until the oil is at the same level as the hole in plate (2). Install plug (3) and the O-Ring seal into plate (2).

Image1.27.1

Image1.27.2

D. Install the rebuilt 359-6795 Hinge Assembly and ladder to the tractor per the applicable steps from Special Instruction REHS4320. "Installing the Ladder on the D11T".

NOTE: Step 18 documents the sequence to install and tighten bolts as well as how to determine if permanent shims are required for non flat fenders. IT IS IMPORTANT THAT THIS SEQUENCE IS FOLLOWED TO:
A) DETERMINE IF THE FENDER IS NOT FLAT.
B) PERMANENTLY INSTALL THE APPROPRIATE SHIMS IF THE FENDER IS NOT FLAT.