PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING XT6-12 HOSE ASSEMBLIES ON CERTAIN FORESTRY MACHINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING XT6-12 HOSE ASSEMBLIES ON CERTAIN FORESTRY MACHINES

Usage:

TEBE4633-00

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24May2016

U-264

A-204

D-236

O-231

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING XT6-12 HOSE ASSEMBLIES ON CERTAIN FORESTRY MACHINES
5057		PS45084

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45084" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

31May2018

PROBLEM

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The XT6-12 hose assemblies may fail on the Affected Product. These hose assemblies, if manufactured from 3/4" XT6ES (161-1835) or ToughGuard (238-8346) bulk hose manufactured from 27-Jul-15 through 31-Oct-15 may fail due to a manufacturing defect. If one of these hose assemblies fail it may develop a pin hole leak or blister of oil within the hose.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
324D FM	JKR01585-01601
324D FM HEEL	JLS01611-01620

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*****Group 2*****
521B	F7B00326-00358
522B	F7C00299-00313, 315-316, 319-321

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*****Group 3*****
325D FM	C7K01494-01499
325D FM BUTT N	C9M01684-01689
325D FM HEEL	C8L01685-01694

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*****Group 4*****
541B	F7D00246-00250, 252

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*****Group 5*****
525D	2L500136, 140-141 GKP00236, 255, 291, 391
545D	KGP00193

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*****Group 6*****
586C	SL500104-00105 SP500119-00120

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
12	6V9746	SEAL-O-RING-ORFS (AS NEEDED)
1	1439798	HOSE AS (IF REQUIRED)
3	1875954	HOSE AS (IF REQUIRED)
2	1875994	HOSE AS (IF REQUIRED)
1	HYD_OIL	HYD OIL (AS NEEDED, UP TO 10L; SEE OMM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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	1P3702	SEAL-RECTANGULAR (AS NEEDED)
186	6V9746	SEAL-O-RING-ORFS (AS NEEDED)
42	2560485	HOSE AS (IF REQUIRED)
2	2560487	HOSE AS (IF REQUIRED)
2	2560488	HOSE AS (IF REQUIRED)
20	2560489	HOSE AS (IF REQUIRED)
2	2560490	HOSE AS (IF REQUIRED)
1	3640485	HOSE AS (IF REQUIRED)
1	3784583	HOSE AS (IF REQUIRED)
20	3784585	HOSE AS (IF REQUIRED)
4	3784586	HOSE AS (IF REQUIRED)
1	HYD_OIL	HYD OIL (AS NEEDED, UP TO 20L; SEE OMM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 3*****
16	6V9746	SEAL-O-RING-ORFS (AS NEEDED)
2	1875954	HOSE AS (IF REQUIRED)
6	1875994	HOSE AS (IF REQUIRED)
1	HYD_OIL	HYD OIL (AS NEEDED, UP TO 10L; SEE OMM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 4*****
24	1P3702	SEAL-RECTANGULAR (AS NEEDED)
118	6V9746	SEAL-O-RING-ORFS (AS NEEDED)
15	2602002	HOSE AS. (IF REQUIRED)
16	2603185	HOSE AS. (IF REQUIRED)
16	2603186	HOSE AS. (IF REQUIRED)
12	2611441	HOSE AS. (IF REQUIRED)
12	2613382	HOSE AS. (IF REQUIRED)
1	HYD_OIL	HYD OIL (AS NEEDED, UP TO 20L; SEE OMM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 5*****
2	1P3702	SEAL-RECTANGULAR (AS NEEDED)
2	6V9746	SEAL-O-RING-ORFS (AS NEEDED)
1	4587169	HOSE AS (IF REQUIRED)
1	4600821	HOSE AS (IF REQUIRED)
1	HYD_OIL	HYD OIL (AS NEEDED, UP TO 10L; SEE OMM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 6*****
2	1P3702	SEAL-RECTANGULAR (AS NEEDED)
2	6V9746	SEAL-O-RING-ORFS (AS NEEDED)
1	4347912	HOSE AS (IF REQUIRED)
1	4347913	HOSE AS (IF REQUIRED)
1	HYD_OIL	HYD OIL (AS NEEDED, UP TO 10L; SEE OMM)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 necessary and see the attached rework procedures.

The impacted hose has a cure date range from 27-Jul-15-6 through 31-Oct-15-6. The cure date is ink jet printed in white ink (Image 1) and can be found on the black portion of the hose surface (not in the hose layline). Prior to removal of the assembly, locate the cure date on the hose. If the date is from 27-Jul-15-6 through 31-Oct-15-6, or if the cure date cannot be found on the hose, remove and replace the assembly following the rework procedure. The cure date of the hose is NOT located on the white tag (Image 2) found on the hose assembly.

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Image1

Image2

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 1
Note: This is a 1.0 hour job to inspect the hoses. Note: Up to 1.5 hours, per hose, will be allowed for hose replacement.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 2
Note: This is a 1.0 hour job to inspect the hoses. Note: Up to 1.5 hours, per hose, will be allowed for hose replacement.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 3
Note: This is a 1.0 hour job to inspect the hoses. Note: Up to 1.5 hours, per hose, will be allowed for hose replacement.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 4
Note: This is a 2.0 hour job to inspect the hoses. Note: Up to 1.5 hours, per hose, will be allowed for hose replacement.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 5
Note: This is a 1.0 hour job to inspect the hoses. Note: Up to 1.5 hours, per hose, will be allowed for hose replacement.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 6*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 6
Note: This is a 1.0 hour job to inspect the hoses. Note: Up to 1.5 hours, per hose, will be allowed for hose replacement.

PARTS DISPOSITION

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

Rework Procedure

1. Park the machine on a hard level surface, and ground the bucket/tool. Refer to the Operation and Maintenance Manual.

2. Ensure that all residual pressure is removed. Refer to the Disassembly and Assembly manual for the machine affected.

3. If the affected (Image1.1.1 to 1.1.6) hose has failed, replace the hose. Inspect all other affected hoses (refer to Images1.1.1 to 1.1.6 to find the hose list for the model being inspected).

4. If the hose has a cure date (Image 1) of 27 - Jul - 15 -6 through 31 - Oct-15 - 6, replace with new hose. Refer to Hydraulic Information System (H.I.S.) and S.I.S. for specific parts numbers for each hose assembly with bulk hose, couplings, O-rings, and flange seals.

NOTE: When the hoses are replaced, 6V-9746 O-rings, and flange seals should be replaced at same time.

NOTE: If it is difficult to find the cure date on the hose then replace the hose.

5. After the rework completion, hydraulic oil level should be checked, add hydraulic oil, if necessary. Please refer to the Operation and Maintenance Manual.