PSP FOR REPLACING THE CASE AND FRAME ASSEMBLY ON CERTAIN D5H AND D5H LGP TRACTORS - PS0388 - MAILED COSA Caterpillar

O-80
7051   PS0388
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.

June 30, 1991

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.

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).

1 - 6Y5313 Case & Frame Assembly
1 - 6Y4989 Tube Assembly
1 - 6Y5161 Tube
2 - 8G5243 Bearing-Sleeve
or
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.

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.

Product Caterpillar Dealer Suggested Customer Suggested
smu Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Cost)  (C/L) (Sell)
0-4000 100% 100 0 20 0 0
4001-6000 50% 75 0 30 25% 15
6001-8000 33 1/3% 50 0 45 50% 25
NOTE: This is a 120-hour job.

Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
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.
****** IMAGE: SEBE4080.00001.001
CAPTION: Illustration 1
-2 of 12-
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.
****** IMAGE: SEBE4080.00001.002
CAPTION: 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.
****** IMAGE: SEBE4080.00001.003
CAPTION: Illustration 3
-3 of 12-
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.
****** IMAGE: SEBE4080.00001.004
CAPTION: Illustration 4
-4 of 12-
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.
****** IMAGE: SEBE4080.00001.005
CAPTION: Illustration 5
19. Remove the welded plate from both fenders and grind the surface smooth.
See Illustration 6.
****** IMAGE: SEBE4080.00001.006
CAPTION: Illustration 6
-5 of 12-
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.
****** IMAGE: SEBE4080.00001.007
CAPTION: 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.
****** IMAGE: SEBE4080.00001.008
CAPTION: Illustration 8
-6 of 12-
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.
****** IMAGE: SEBE4080.00001.009
CAPTION: Illustration 9
-7 of 12-
29. Remove the steering clutch and brake control valve. See Illustration
10.
****** IMAGE: SEBE4080.00001.010
CAPTION: Illustration 10
30. Remove the pivot shaft groups. See Illustration 11.
****** IMAGE: SEBE4080.00001.011
CAPTION: Illustration 11
-8 of 12-
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.
****** IMAGE: SEBE4080.00001.012
CAPTION: Illustration 12
32. Remove the equalizer bar group. See Illustration 13.
****** IMAGE: SEBE4080.00001.013
CAPTION: Illustration 13
-9 of 12-
33. Position the new case and frame assembly on suitable stands. See
Illustration 14.
****** IMAGE: SEBE4080.00001.014
CAPTION: Illustration 14
34. Install the new 8G5243 Bearing (PAT Bulldozer) or 8G5427 Bushing (S
Bulldozer) in the case and frame assembly. See Illustration 15.
****** IMAGE: SEBE4080.00001.015
CAPTION: Illustration 15
-10 of 12-
35. Install the new 6Y5161 Tube (dipstick guide) in the case. See
Illustration 16.
****** IMAGE: SEBE4080.00001.016
CAPTION: Illustration 16
36. Install the new 6Y4989 Tube for the power train lines group. See
Illustration 17.
****** IMAGE: SEBE4080.00001.017
CAPTION: Illustration 17
-11 of 12-
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.
****** IMAGE: SEBE4080.00001.018
CAPTION: 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.
****** IMAGE: SEBE4080.00001.019
CAPTION: Illustration 19
-12 of 12-
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.