PRODUCT SUPPORT PROGRAM FOR REPLACING THE 8T-4193 BOLTS ON CERTAIN 279C, 289C, 299C COMPACT TRACK LOADERS AND 277C, 287C, 297C MULTI TERRAIN LOADERS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 8T-4193 BOLTS ON CERTAIN 279C, 289C, 299C COMPACT TRACK LOADERS AND 277C, 287C, 297C MULTI TERRAIN LOADERS
Usage:
REBE5599-03
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11Jan2010
(Revised 06May2010)
U-15
A-11
D-12
O-15
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Before/After
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 8T-4193 BOLTS ON CERTAIN 279C, 289C, 299C COMPACT TRACK LOADERS AND 277C, 287C, 297C MULTI TERRAIN LOADERS
3282
PS43018
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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 "PS43018" 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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NOTE:
This Revised Service Letter replaces the 11Jan2010 (Revised 28Jan2010) Service Letter. Changes have been made to the Affected Product, Rework Procedure, Parts Needed, and Service Claim Allowances.
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TERMINATION DATE
31Jan2012
PROBLEM
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The existing 8T-4193 Bolts can loosen on certain 279C, 289C, and 299C Compact Track Loaders and 277C, 287C, and 297C Multi Terrain Loaders. If the existing bolts loosen, it can shear the inside mounting bolts and cause structural damage to the torsion axles.
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.
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 attached Rework Procedure.
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SERVICE CLAIM ALLOWANCES
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-2000 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
1 hour is allowed to verify torque of the bolts. An extra 4 hours will be allowed for each axle that needs to be replaced. An additional 6 hours will be allowed if the 8T-3597 weld nuts on the rear frame rails located along the bottom of the engine compartment are affected (Illustration 1.2.1, Item C).
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-2000 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 2
1 hour is allowed to verify torque of the bolts. An extra 4 hours will be allowed for each axle that needs to be replaced. An additional 6 hours will be allowed if the 8T-3597 weld nuts on the rear frame rails located along the bottom of the engine compartment are affected (Illustration 1.2.1, Item C).
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
- Place the machine on stands.
- Remove the 304-1825 End Caps (for CTLs), or the 230-3729 Spacers and 258-3009 Caps (for MTLs), and slide the undercarriages away from the machine frame slightly to allow access to the outer mounting bolts.
- NOTE: Bolt torque inspection can be done without sliding undercarriage away from frame. A 2 ft. socket extension with swivel head and a box end extension can be used to access all outer mounting bolts while the machine is sitting on flat ground.
Image1.1.1
- Perform a static torque inspection for the 8T-4193 Outer Mounting Bolts (Image 1.2.1, items A,B). Apply the torque in the tightening direction. The bolts should not move when a torque of 200 Nm is applied.
- If the 8T-4193 Outer Mounting Bolts (A,B) do not move, no further action is required and the repair is complete. Slide the undercarriages back into position and re-install the 304-1825 End Caps (for CTLs), or the 230-3729 Spacers and 258-3009 Caps (for MTLs).
- If the 8T-4193 Outer Mounting Bolts (A,B) are loose, bolts should be replaced and tightened to a torque of 240 Nm. Before re-installing new bolts, check for further damage to axle, weld nuts, or bolt holes. The most common failures are cracks in the welds of the axle mounting brackets and distortion of the axle mounting bolt holes. If damage is found, use repair procedures listed below. Additionally, perform a static torque inspection for the 8T-4183 Inner Mounting Bolts (Image 1.2.1, item C). The bolts should not move when a torque of 80 Nm is applied.
- If the 8T-4183 Inner Mounting Bolts (C) are loose, and there is no damage to the axles and/or frame, replace the 8T-4183 Inner Mounting Bolts. Tighten the bolts to a torque of 100 +/- 20 Nm. Tighten the 8T-4193 Outer Mounting Bolts (A,B) to 240 Nm. Slide the undercarriages back into position and re-install the 304-1825 End Caps (for CTLs), or the 230-3729 Spacers and 258-3009 Caps (for MTLs).
SPECIFIC REWORK PROCEDURES Use Image 1.2.1 to identify your specific failure location. Then, choose the rework procedure listed below for that location.
AXLE REPLACEMENT PROCEDURE - Replace the appropriate axle. For CTL?s, refer to Disassembly and Assembly Manual, KENR8831, "Axle (Rear) ? Remove and Install", and/or "Axle (Front) ? Remove and Install".
For MTLs, refer to Disassembly and Assembly Manual, KENR5197, "Idler Axle ? Remove ? Front" and "Idler Axle ? Install ? Front", and/or "Idler Axle ? Remove ? Rear" and "Idler Axle ? Install ? Rear".
- If the holes for the 8T-4193 Outer Mounting Bolts (A,B) have not been deformed or the weld nuts have not been damaged, install new 8T-4193 Outer Mounting Bolts (A,B) and tighten to a torque of 240 Nm. Slide the undercarriages back into position and re-install the 304-1825 End Caps (for CTLs), or the 230-3729 Spacers and 258-3009 Caps (for MTLs).
- If the holes for the 8T-4193 Outer Mounting Bolts (A,B) have been deformed or the 9X-6269 Weld Nuts (Image 1.2.1, item A) have been damaged, perform the appropriate repair procedure based on failure location. The axle will need to be removed in order to perform this procedure.
BOLTED JOINT REPAIR PROCEDURE Failure Location: A - If the 9X-6269 Weld Nuts (A) for the rear outer mounting bolts have been damaged, drill 2 working holes on either side of the bolt hole. Refer to Image 1.3.1.
- Snug new 9X-6269 Nut (A) to the frame using a spare bolt.
- Tack weld nut in 2 locations through the working holes.
- Remove the spare bolt.
- Fill the working holes with weld and grind flush.
- Repeat as needed for other broken weld nuts.
- Install the axles. Refer to Disassembly and Assembly Manual, KENR8831 (for CTLs) or Disassembly and Assembly Manual, KENR5197 (for MTLs). Install new 8T-4193 Outer Mounting Bolts (A) and tighten to a torque of 240 Nm. Slide the undercarriages back into position and re-install the 304-1825 End Caps (for CTLs), or the 230-3729 Spacers and 258-3009 Caps (for MTLs).
Image1.3.1
NOTE: The 9X-6269 Weld Nut (A) for the bottom rear bolt on the 304-1853 and 304-1854 axles (Image 1.2.1, items 1,3) is located inside the engine compartment for the 277C, 287C, 279C, and 289C. If this weld nut fails, access to this location for repair is difficult. The alternative mounting hole location shown in Image 1.4.1 can be used if you cannot effectively access the standard location. Once the new bolt hole is created, weld a new weld nut into location using the procedure previously described in this section.
Image1.4.1
Failure Location: B - If the front outer mounting bolt holes have been deformed, drill holes on the frame and axle out to 20.5mm. Install 8T-9399 Bolts, 6V-8182 Nuts, and 154-1580 Washers into the drilled holes and tighten to a torque of 370 +/- 50 Nm.
Failure Location: C - If the 8T-3597 Weld Nuts (Image 1.2.1, item C) on the rear frame rails located along the bottom of the engine compartment fail, the hydraulic pump stack and hydraulic tank must be removed to access location for repair. Refer to the following publications for the proper removal and installation procedures.
? MTL: Disassembly and Assembly Manual, KENR5197, "Piston Pump (Hydrostatic) ? Remove" and "Piston Pump (Hydrostatic) ? Install"
Once you have gained access to the affected weld nut, grind the area around the weld nut smooth. Use an 8T-4778 Locknut in place of an 8T-3597 Weld Nut.
