PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE AFTERCOOLER ON CERTAIN D8T TRACK-TYPE TRACTORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE AFTERCOOLER ON CERTAIN D8T TRACK-TYPE TRACTORS

Usage:

REBE7550-02

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21Mar2012

(Revised 05Jun2012)

U-151

A-126

D-135

O-146

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE AFTERCOOLER ON CERTAIN D8T TRACK-TYPE TRACTORS
1063		PS43545

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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 "PS43545" 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 21Mar2012 (Revised 20Apr2012) Service Letter. Changes have been made to the Service Claim Allowances.

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TERMINATION DATE

31Mar2014

PROBLEM

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The existing aftercooler can crack on certain D8T Track-Type Tractors. If the existing aftercooler fails it can allow water into the engine inlet, leading to engine hydraulic lock.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
D8T	J8B00204-01497, 1499-1893, 1895-1956, 2204-2544, 2546-2645, 2647-3144 KPZ00004, 6-8, 325-363, 365-559, 561-639, 641-728, 731-869, 872-936, 938-1165, 1167, 1169-1190, 1192-1295, 1297-1369, 1372-1487, 1489-1569, 1571-1806, 1808-1873, 1875-1901, 1903-1962, 1964-2463, 2465-2575, 2577-2670, 2672-2815, 2817-2836, 2838-3002, 3004-3182, 3184-3276, 3278-3338, 3500-3527, 3529-3600, 3602-3618, 3620-3705, 3707-3828, 3831-3840, 3842-3891, 3893-3926, 3928-4171

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*****Group 2*****
D8T	J8B01498, 1894, 2545, 2646 KPZ00364, 560, 640, 729-730, 870-871, 937, 1166, 1168, 1191, 1296, 1370-1371, 1488, 1570, 1807, 1874, 1902, 1963, 2464, 2576, 2671, 2816, 2837, 3003, 3183, 3277, 3528, 3601, 3619, 3706, 3829-3830, 3841, 3892, 3927

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	6I2435	SPACER
1	6I2436	RETAINER
4	7X7729	WASHER-HARD
2	8T4136	BOLT-HEX HEAD
2	8T4189	BOLT-HEX HEAD
2	8T4195	BOLT-HEX HEAD
2	8T4896	WASHER-HARD
4	8T4910	BOLT-HEX HEAD
4	9M1853	MOUNT AS.
1	2098364	AFTERCOOLER AS
8	2432076	WASHER-HARD
1	3831734	BAFFLE AS
1	3831735	BLOCK
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 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*****
1	6I2435	SPACER
1	6I2436	RETAINER
4	7X7729	WASHER-HARD
2	8T4136	BOLT-HEX HEAD
2	8T4189	BOLT-HEX HEAD
2	8T4195	BOLT-HEX HEAD
2	8T4896	WASHER-HARD
4	8T4910	BOLT-HEX HEAD
4	9M1853	MOUNT AS.
8	2432076	WASHER-HARD
1	2672910	AFTERCOOLER AS
1	3831734	BAFFLE AS
1	3831735	BLOCK
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 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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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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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%
*****Group 1*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 11.0-hour job for Group 1

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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%
*****Group 2*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 11.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

Lower the front bolted bottom guard, remove the hood, unbolt the A/C condenser from the Air to Air Aftercooler (ATAAC) (if applicable), remove the inlet and outlet lines, and remove the ATAAC from the machine. The mounting hardware will not be reused.

Inspect the ATAAC for cracks around the bottom tank. If no visible cracks are present, pressure test the ATAAC (ref SENR9832, D8T Test & Adjust, Aftercooler Core Leakage). If ATAAC does not pass the pressure test, order a new ATAAC.

Increase the size of the ATAAC mount holes in the bottom tank to 31.75mm. Add a chamfer on the top and bottom of the bore. Insert the 9M-1853 Rubber Mounts into the bores.

Image1.3.1

Install the 383-1734 Baffle, using two 8T-4189 Bolts and two 8T-4896 Washers, onto the underside of the 383-1735 Block.

Image1.4.1

Using two 8T-4195 Bolts and two 7X-7729 Washers, install the block/baffle assembly to the retainer plate using the two mount holes previously used for the top ATAAC mount.

Image1.5.1

Install the ATAAC using four (each) 8T-4910 Bolts with a 243-2076 Washer on either side of the rubber mount at the bottom. Use a new 6I-2436 Retainer for restraining the top of the ATAAC, bolting the 6I-2435 Mount to the block. Reinstall lines and guards.

Group Number 2

Reference rework procedure for Group 1. If installing a new ATAAC, the grid on the front side of the ATAAC will need to be transferred.