Product Support Program For Replacing The Case And Frame Assembly On Certain D5H and D5H LGP Tractors Caterpillar

Product Support Program For Replacing The Case And Frame Assembly On Certain D5H and D5H LGP Tractors

Usage:

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Caterpillar: Confidential Yellow

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.

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0388" as Part Number "7755" as Group Number, and "96" as Description Code.

Termination Date

June 30, 1991

Problem

Cracks may develop along the welds and inside walls of the case and frame assembly on certain D5H and D5H LGP Tractors used in rough terrain and/or high impact conditions. The cracks may result in oil leaking from the joint between the pivot shaft flange and the case, oil leaking through the pivot shaft mounting bolt holes, or the oil level in the transmission case may continuously decrease without external leaks. If the oil leaks become visible and the constant addition of oil to the transmission is necessary, the case and frame can be replaced.

Affected Product
Model & Identification Number

D5H (8RC1-1865; 7NC1-601; 9HC1-252; 1DD1-694; 1YD1-613; 3MD1-699; 2SD1-548)

D5H LGP^* (4KD1-507)

^*This Program does not apply to D5H LGP Tractors equipped with a 8Z7528 or 8Z7530 Modification (D5H Custom Skidders).

Parts Needed

1 - 6Y5313 Case & Frame Assembly

1 - 6Y4989 Tube Assembly

1 - 6Y5161 Tube

2 - 8G5243 Bearing-Sleeve

2 - 8G5427 Bushing

NOTE: The case and frame assemblies are in limited supply and will be allocated as needed until sufficient quantities are available.

NOTE: Additional parts may be required to convert from internally routed to externally routed lift cylinder lines. See Special Instructions SEHS8983 to determine which parts are required for the lines group that the Affected Product is equipped with.

Action Required

See the following notes and the attached procedure.

NOTE: The case and frame assembly can be done as a scheduled repair at the same time as other major service work or while implementing other Programs.

NOTE: The Product Identification Number must be moved to the new case and frame assembly.

NOTE: Parts showing damage or wear other than the parts listed under the heading Parts Needed should be replaced at the dealers discretion.

Service Claim Allowances

NOTE: This is a 120-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Follow the procedures in the Service Manual and in this procedure to replace the case and frame assembly.

NOTE: Make sure all lines are cleaned before disconnecting and that they are capped to prevent entry of dirt. If dirt enters any of the lines, make sure they are cleaned before they are installed on the new case and frame assembly. Install new gaskets and seals as necessary.

1. Remove the drawbar group and the bulldozer blade.

2. Remove the bottom guard groups.

3. Clean and dry the tractor.

4. Place the tractor in an appropriate area. All components and groups will need to be removed from the tractor.

5. Obtain appropriate stands. The recommended stand height is about 850 mm (33.5").

6. Release any pressure from the hydraulic system and air conditioner group.

7. Remove the tracks from the tractor.

8. Remove the track roller frames.

9. Place appropriate supports under the pivot shafts. See Illustration 1 for reference.

Illustration 1

10. Position suitable stands under the C-frame to support it. Disconnect the lift, tilt, and angle cylinder lines groups. Remove the lift cylinders. See Illustration 2.

Illustration 2

11. Fasten a suitable hoist to the C-frame group. Remove the inside and outside hinge pins and the C-frame group from the tractor. See Illustration 3.

Illustration 3

12. Drain the coolant, hydraulic oil, power train oil, and final drive oil. Shut off the fuel supply valve.

13. Follow the procedure in the Service Manual and remove the axles.

14. Follow the procedure in the Service Manual and remove the steering clutches and brakes.

15. Follow the procedure in the Service Manual and remove the transmission and bevel gears.

16. Follow the procedure in the Service Manual and remove the fuel tank.

17. Disconnect the battery cables, wiring, and windshield washer lines tube. Remove the left hand fender group with the battery. See Illustration 4.

Illustration 4

18. Disconnect the tube and hose assemblies from the hydraulic tank. Remove the right hand fender and hydraulic tank as a group. See Illustration 5.

Illustration 5

19. Remove the welded plate from both fenders and grind the surface smooth. See Illustration 6.

Illustration 6

20. Follow steps 4 thru 13 and 14 thru 18 of the Remove Cab procedure in the Service Manual.

21. Disconnect the tube and hose assemblies from the valve. See Illustration 7.

Illustration 7

22. Follow steps 20 thru 23 of the Remove Cab procedure in the Service Manual.

23. Attach a hoist to the cab at the three lifting brackets.

24. Remove the ROPS support mounting bolts. Remove the cab and ROPS as a unit. Lift slowly and make sure all necessary components have been disconnected. See Illustration 8.

Illustration 8

25. Follow the procedure in the Service Manual and remove the radiator.

26. Follow the procedure in the Service Manual and remove the air cleaner assembly.

27. Follow steps 3 thru 40 of the Remove Engine procedure in the Service Manual.

28. Remove the power train filter group with the hose assemblies attached. See Illustration 9.

Illustration 9

29. Remove the steering clutch and brake control valve. See Illustration 10.

Illustration 10

30. Remove the pivot shaft groups. See Illustration 11.

Illustration 11

31. If the tractor is equipped with sound suppression, remove the two brackets from the case and frame so they can be installed on the new. See Illustration 12.

Illustration 12

32. Remove the equalizer bar group. See Illustration 13.

Illustration 13.

33. Position the new case and frame assembly on suitable stands. See Illustration 14.

Illustration 14

34. Install the new 8G5243 Bearing (PAT Bulldozer) or 8G5427 Bushing (S Bulldozer) in the case and frame assembly. See Illustration 15.

Illustration 15

35. Install the new 6Y5161 Tube (dipstick guide) in the case. See Illustration 16.

Illustration 16

36. Install the new 6Y4989 Tube for the power train lines group. See Illustration 17.

Illustration 17

37. Remove the linkage groups, covers, and transmission filter group from the former case and frame assembly and install them on the new one. See Illustration 18.

Illustration 18

38. Remove the hydraulic lines group, power train lines group, and fuel lines group from the former case and frame assembly and install them on the new one. See Illustration 19.

Illustration 19

39. Install the remainder of the modules, groups, and components in the reverse order that they were removed.

NOTE: If the tractor is equipped with internally routed lift cylinder lines, follow the procedure in Special Instructions SEHS8983 and convert from internally routed lines to externally routed lines.

40. Fill all systems with the correct oils or coolants. See the Service Manual.

41. Check the operation of the tractor to make sure all systems and components are functioning correctly. Make any adjustments that are necessary.

42. Check all fluid levels again to make sure they are correct.