PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOTTOM GUARD RETAINERS ON CERTAIN D6T TRACK TYPE TRACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOTTOM GUARD RETAINERS ON CERTAIN D6T TRACK TYPE TRACTORS

Usage:

REBE8481-01

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20Aug2012

(Revised 03Oct2012)

U-435

A-347

D-374

O-403

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOTTOM GUARD RETAINERS ON CERTAIN D6T TRACK TYPE TRACTORS
5104 5057 7153		PI32081

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32081" 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 "PI32081" 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:

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 20Aug2012 Service Letter. Changes have been made to clarify the Affected Product, Parts Needed, Service Claim Allowances, and Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
28Feb2013	31Aug2013

PROBLEM

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The 328-3329 Bottom Guard Loops (plates) on certain D6T Track-Type Tractors were changed to increase their inboard depth for improved bottom guard assembly. This inadvertently created an issue that can cause interference between the 217-3655 Bottom Guard Retainers and two hydraulic lines. It also increases the possibility for the 8C8478 Bottom Guard Bolts to spin freely during bottom guard removal and installation.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
D6T LGP PAT	KSB00317-00414
D6T XL PAT	DTD00196-00227
D6T XW PAT	RCW00266-00308

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*****Group 2*****
D6T LGP	ZJB00299-00406
D6T LGP OEM	PLR00100-00111
D6T XL	GMK00411-00534
D6T XW	SLJ00186-00248, 250-265, 272-274, 280-291

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
14	8C8478	BOLT-HEX HEAD (1-14 Use Only if Required)
14	8T4131	NUT-HEX (1-14 Use Only if Required)
1	8T4196	BOLT-HEX HEAD
14	8T5439	WASHER-HARD (1-14 Use Only if Required)
1	1984777	WASHER-HARD
14	3915964	RETAINER AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
2	4J5267	SEAL-O-RING
2	6V9746	SEAL-O-RING-ORFS
14	8C8478	BOLT-HEX HEAD (1-14 Use Only if Required)
14	8T4131	NUT-HEX (1-14 Use Only if Required)
1	8T4196	BOLT-HEX HEAD
14	8T5439	WASHER-HARD (1-14 Use Only if Required)
1	1984777	WASHER-HARD
1	3913029	TUBE AS.
1	3913030	TUBE AS.
14	3915964	RETAINER AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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 Service Manual if/as needed and see the attached Rework Procedure to replace the bottom guard retainers, hydraulic lines, and hardware.

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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 3.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 3.5-hour job for Group 2

PARTS DISPOSITION

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOTTOM GUARD RETAINERS ON CERTAIN D6T TRACK-TYPE TRACTORS

MODELS INVOLVED - D6T Track-Type Tractors

Dear Caterpillar Product Owner:

The 328-3329 Bottom Guard Loops (plates) on certain D6T Track-Type Tractors were changed to increase their inboard depth to improve assembly. This inadvertently created an issue that can cause interference between the 217-3655 Bottom Guard Retainers and multiple hydraulic lines. It also increases the possibility for the 8C8478 Bottom Guard Bolts to spin freely during bottom guard removal and installation. If bolts are found to be free spinning they must be replaced along with adding new 391-5964 Retainers.

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 20Aug2012 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 20Aug2012 Service Letter

Rework Procedure

1. Remove all three bottom guards. Refer to Disassembly and Assembly, KENR5130, "Bottom Guard - Remove"

2. Remove the 14 existing 217-3655 Bottom Guard Retainers and save until the rework procedure is complete. These retainers may be reused in certain conditions. The remaining hardware will be reused unless it was damaged during the bottom guard removal.

3. Install 14 new 391-5964 Retainers ensuring that the thick side is facing outboard as shown in Image 1.3.1. Reuse the original hardware as directed above in step 2. If the bolt is tilted because the new retainer is pushing it too far inboard, consider reusing the 217-3655 Retainer at these particular joints.

Image1.3.1

4. More clearance is needed between the fan hose and the new retainer. From underneath the front, left-hand-side of the machine remove the original bolt securing the two-piece clip to the frame rail. Reference Image 1.4.1.

Image1.4.1

5. Assemble the hose and clamp using the new 8T-4196 Bolt and 198-1477 Spacer as shown in Image 1.5.1.

Image1.5.1

Follow Steps 6-8 to replace the tilt tubes are for Group 2 only. (Machines with serial number prefixes GMK, SLJ, ZJB, or PLR)

6. More clearance is needed between the tilt tubes and the new retainer. From underneath the front, right-hand-side area of the machine remove the existing 325-1629 and 325-1630 Tilt Tubes. These tubes will not be reused. The existing hardware will be reused.

7. Assemble the new o-ring seals to the tubes. 4J-5267 O-ring Seals should be installed at the tilt manifold end of each tube and 6V-9746 O-ring Seals should be installed at the tilt hose end of each tube.

8. Install the new 391-3029 and 391-3030 Tube Assemblies. Secure them to the mounting point with the original 2 piece clip, grommet, bolts, and washers. At the manifold end, attach the tubes with the original flanges, bolts, and washers. Reference Image 1.8.1 **Note: Two washers must be installed on each flange bolt to ensure required wrench clearance for the bolt heads. Reference Image 1.8.2

Image1.8.1

Image1.8.2

9. Install all three bottom guards. Refer to Disassembly and Assembly, KENR5130, "Bottom Guard - Install". Belly guard bolts should be tightened to a torque of 370 Nm +/- 50 Nm (275 lb ft +/- 35 lb ft).