PSP FOR REPAIR OF CRACKS AND REINFORCEMENT OF THE CASE AND FRAME ASSEMBLY ON D5H CUSTOM SKIDDERS - PS4448 - MAILED US, CAN ADA Caterpillar

U-81
7051   PS4448
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair, use
"PS4448" as Part Number, "7755" as Group Number, and "96" as
Description Code.

April 30, 1992

Cracks can occur in the plates used in the case and frame assembly on D5H
Custom Skidders. Reinforcement plates can be added to the case and frame
assembly.
NOTE: This reinforcement should be done if external
power train oil leaks occur in the corners of the
inner rail assembly side plate and the front of the
case, near the formed gussets, which were added when
the reinforcement described in Service Letter
PS4265 was done.

Model Identification Number
D5H* 4KD1-500
* Only if Equipped With 8Z7530 Modification Arrangement (D5H Custom Skidder)
and PS4265 has been completed

Seven items need to be fabricated for each tractor. See the attached
procedure.
Parts are limited to seals, gaskets, etc necessary to assemble the machine.
If external lines are to be installed, See Step 15 of the rework procedure,
and order the necessary items listed in Special Instruction SEHS8983 (-01).

See the attached procedure.

Product Caterpillar Dealer Suggested Customer Suggested
smu Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Cost)  (C/L) (Sell)
0-4500 100% 150 0 0 0 0
NOTE: This is a 150-hour job. A maximum of $175.00 US will be allowed
for materials to fabricate the plates. Parts are limited to
seals, gaskets, etc. necessary to assemble machine.

All parts removed (with the exception of cores used for Caterpillar
Remanufactured parts) should be rendered useless and scrapped immediately
upon completion of the repair.
Rework Procedure
Fabricate Items 1-5 (plates) shown in the illustrations, using structural
steel with a minimum yield point of 32000 PSI and a minimum tensile strength
of 58000 PSI. ASTM A36, ASTM576 (SAE 1018) steel meets this requirement.
Fabricate Items 6 and 7 (Plates) shown in the illustrations, using mild
steel.
Items 1 & 2 and 6 & 7 are respectively paired for left hand and right hand
side reinforcements and one each is required. The only difference between
them is the location of the chamfers (1 & 2) and the direction of the bend (6
& 7).
All dimensions are in millimeters. Some of the plates may need grinding in
certain areas to provide proper fit.
Material Item Numbers
16 mm thick plate 1, 2
10 mm thick plate 3, 4, 5
3 mm thick plate 6, 7
Welding Recommendations
Argon-Arc Welding
AWS A5.18 Class ER70 S-5, or better, solid wire.
Rod Welding
E7018
****** IMAGE: SEBE4284.00001.001
CAPTION: Item #1
****** IMAGE: SEBE4284.00001.002
CAPTION: Item #2
****** IMAGE: SEBE4284.00001.003
CAPTION: Item #3
****** IMAGE: SEBE4284.00001.004
CAPTION: Item #4
****** IMAGE: SEBE4284.00001.005
CAPTION: Item #5
****** IMAGE: SEBE4284.00001.006
CAPTION: Item #6
****** IMAGE: SEBE4284.00001.007
CAPTION: Item #7
D5H Custom Skidder Reinforcement Procedure
NOTE: Use the D5H Service Manual and the Supplementary
Product Support Literature (SEBF0570) in conjunction
with these instructions to complete the procedure.
1. Separate the track and remove.
2. Remove the track roller frames and pivot shafts.
3. Remove the grapple arch and winch.
4. Remove the final drives and steering clutch and brakes.
5. Remove the transmission, transmission guide tubes and power train
suction line.
6. Remove the rear bottom guard and torque converter.
7. Remove the steering clutch and brake control valve.
8. Remove all hydraulic lines, etc. which interferes with completion of the
rework.
9. Protect all open lines and ports from foreign objects.
10. Mark the bottom guard mounting plates with a center punch as shown in
Illustration 1. Cut the guard in two and remove the rear section. The
pieces will be reused later in the procedure.
11. Remove the formed gussets, triangle shaped plates and reinforcement
plates shown in Illustration 1.
12. Pressurize the pivot shaft cavities as follows:
A) Coat all of the pivot shaft mounting bolts with sealant (RTV) and
install them in the case.
B) Drill and tap a hole in one of the bolts or in the mounting face of
the pivot shaft casting to accept a fitting on which an air
regulator can be mounted. See Illustration 2.
C) Attach a regulator to the fitting.
D) Attach an air pressure hose to the regulator.
E) Pressurize the cavity to 20 PSI.
13. Identify the location of any cracks using a soap solution. Mark the
location.
14. Weld repair the cracks identified in Step 13 and the undercuts made in
Step 11.
15. If the cracks are inaccessible due to the position of the bulldozer lift
cylinder tubes, the tubes can be removed and replaced with external
lines using the procedure described in Special Instruction SEHS8983-01.
16. Pressurize the cavity and inspect the weld repairs. Static pressure
must be maintained.
17. When all cracks are repaired, locate and weld Items 1 and 2 to the frame
assembly using the dimensions in Illustration 3.
18. Locate and weld Items 3, 4, and 5 using the dimensions in Illustration
4.
19. Locate and weld Items 6 and 7 using dimensions in Illustration 5. The
weld must be air tight.
20. Locate the parts removed in Step 10. Prepare the weld joints by
grinding chamfers on the ends. Using the alignment marks, weld to the
rail assembly and to each other. See Illustration 6.
21. Paint all reworked areas.
22. Assemble the components removed in Steps 1 through 8.
****** IMAGE: SEBE4284.00001.008
CAPTION: Illustration 1
****** IMAGE: SEBE4284.00001.009
CAPTION: Illustration 2
****** IMAGE: SEBE4284.00001.010
CAPTION: Illustration 3
****** IMAGE: SEBE4284.00001.011
CAPTION: Illustration 4
****** IMAGE: SEBE4284.00001.012
CAPTION: Illustration 5
****** IMAGE: SEBE4284.00001.013
CAPTION: Illustration 6