PRODUCT IMPROVEMENT PROGRAM FOR RELOCATING THE BACKUP ALARM ON CERTAIN D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, AND D6T P LGP TRACK-TYPE TRACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR RELOCATING THE BACKUP ALARM ON CERTAIN D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, AND D6T P LGP TRACK-TYPE TRACTORS

Usage:

REBE7590-00

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07Nov2011

U-490

A-401

D-431

O-433

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR RELOCATING THE BACKUP ALARM ON CERTAIN D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, AND D6T P LGP TRACK-TYPE TRACTORS
1408 1401 1402 4150 7180 1273 7150		PI10876

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10876" 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 "PI10876" 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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PROBLEM

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The backup alarm on D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, and D6T P LGP Track-Type Tractors equipped with a 256-6020 or 265-5211 Rear Striker Bar may need to be relocated. The backup alarm in its existing position may not be sufficiently audible to warn personnel of the potential hazard of a machine in reverse motion and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
D6T	JHB00143, 350, 449 PEZ00239, 335, 411, 439, 661, 675 SMC00282-00284
D6T LGP	KJL00405, 407, 444-445, 466, 483, 558, 572, 575, 611-612, 636, 654-656, 712, 789, 804-805, 814-815, 817, 846, 856, 862, 920, 937, 952, 968, 1048, 1059, 1070, 1072, 1083-1084, 1087, 1091, 1098, 1102, 1111, 1145, 1188-1189, 1215, 1233-1234, 1250, 1254, 1257, 1260, 1262-1263, 1288-1294 LKJ00203, 384-385
D6T P LGP	WCG00342, 387, 401, 403-404, 469, 486, 574, 581, 583, 587
D6T P XL	WFH00312
D6T P XW	DJG00326, 392, 471, 523, 530
D6T XL	GCT00497-00498, 688, 692 LAE00225, 301, 546 LAY00510, 1181-1182, 1218, 1273, 1284, 1374, 1437, 1444, 1446, 1455, 1484, 1515, 1522, 1524, 1548, 1560, 1578-1579, 1602, 1613, 1636-1638, 1649, 1658-1659, 1664-1667
D6T XW	SKL00549, 568, 601, 624, 650-651, 654, 659-663, 666-671, 673, 681-686, 688, 698-699, 712-713, 719-722, 733-736, 747-748, 754-762

PARTS NEEDED

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Qty	Part Number	Description
1	4C4200	PAINT-YELLOW
2	4P8134	CLIP-LADDER
3	5P1075	WASHER-HARD
2	5P1076	WASHER-HARD
4	6V1820	BOLT
9	7K1181	STRAP-CABLE
3	7T1099	LINK
2	8T3597	NUT-WELD
4	8T4121	WASHER-HARD
1	8T4136	BOLT-HEX HEAD
2	8T4137	BOLT-HEX HEAD
2	8T4139	BOLT-HEX HEAD
1	1313981	GUARD
1	2207167	GUARD AS.
1	3750254	BRACKET AS
1	3751381	HARNESS AS
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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Perform the backup alarm relocation described in the rework procedure on certain D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, and D6T P LGP Track-Type Tractors equipped with a 256-6020 or 265-5211 Rear Striker Bar.

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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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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 1.5-hour job

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR RELOCATING THE BACKUP ALARM ON CERTAIN D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, AND D6T P LGP TRACK-TYPE TRACTORS

MODELS INVOLVED - D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, AND D6T P LGP TRACK-TYPE TRACTORS

Dear Caterpillar Product Owner:

The backup alarm on D6T, D6T XL, D6T XW, D6T LGP, D6T P XL, D6T P XW, and D6T P LGP Track-Type Tractors equipped with a 256-6020 or 265-5211 Rear Striker Bar may need to be relocated. The backup alarm in its existing position may not be sufficiently audible to warn personnel of the potential hazard of a machine in reverse motion and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. 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 07Nov2011 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 07Nov2011 Service Letter

Rework Procedure

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The steps below describe the modifications necessary to relocate the backup alarm from the inside of the rear striker box to the new position on the right hand fuel tank guard. The existing backup alarm and electrical harness connection will be used in the modication.

1. Remove the 255-1137 Rear Right Hand Fuel Tank Guard. Use Image 1.1.1 as a reference to make the following modifications to the guard and re-assemble the modified guard to the tractor.
a) Make (2) 16.75 mm diameter holes in the locations shown. Another hole diameter may be used as long as it is large enough to accept the pilot diameter of the weld nut used in the next step.
b) Locate the (2) 8T-3597 Weld Nuts on the inside of the guard using the pilot diameters and attach using (2) 3 mm fillet welds on each nut.
c) Attach (3) 7T-1099 Links using (2) 3 mm fillet welds on each link.
d) Touch up the paint as needed using the 4C4200 Paint.

Image1.1.1

2. Remove the existing 220-0230 Backup Alarm. It will be reused.

3. Subassemble the 220-0230 Alarm and guard as shown in Image 1.2.1.

Image1.2.1

4. Connect the 375-1381 Harness to the alarm, secure the electrical connector and alarm pigtail to the ladder clip using a 7K-1181 Cable Strap, and attach the backup alarm guard subassembly to the fuel tank guard as shown in Image 1.3.1 using (2) 8T-4139 Bolts and (2) 5P-1076 Washers.

Image1.3.1

5. Route and secure the harness using the hardware and path shown in Image 1.4.1. Route the remainder of the harness behind the fuel tank down to the original alarm electrical connector and connect it. Image 1.4.2 shows a completed modification.

6. Perform a backup alarm functional test.