PRODUCT SUPPORT PROGRAM FOR UNDERCARRIAGE SWING LINK PIN/BEARING REPLACEMENT ON CERTAIN CH35, CH45, AND CH55 CHALLENGER TRACTORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UNDERCARRIAGE SWING LINK PIN/BEARING REPLACEMENT ON CERTAIN CH35, CH45, AND CH55 CHALLENGER TRACTORS

Usage:

SEBE6966-06

July 25, 1999
(Revised August 2003)
U-208
A-168
AU-141
S-116
H-85
O-181

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR UNDERCARRIAGE SWING LINK PIN/BEARING REPLACEMENT ON CERTAIN CH35, CH45, AND CH55 CHALLENGER TRACTORS
4186		PS4933

NOTE: This Program can 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 "PS4933" as the Part number and "7755" as the Group Number. If adminstered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If adminstered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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 Revised Service Letter replaces the July 25, 1999 (Revised August 2002) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

July 31, 2005

PROBLEM

Improvements have been made to the front idler swing link pin/adjusting lever area of the undercarriage. The new 161-8559 Swing Link Pin is now retained with snap rings on both ends, as well as with setscrews. The setscrews now tighten against a machined flat instead of a radial groove. These changes will provide improved pin retention. In addition, the setscrews have been changed from an internal hex to an external hex head. The new 1460852 Adjuster also has an external head rather than the former internal hex. This allows the use of a standard external hex socket to loosen or adjust the setscrew.

AFFECTED PRODUCT

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Model	Identification Number
CH35	8DN1-881, 897-920, 935-1000
CH45	1DR1-1767, 1793-1901, 1935-2053
CH55	7DM1-954, 975-1710

PARTS NEEDED

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Qty	Part Number	Description
1	4C9506	COMPOUND
2	4D4431	BEARING
4	8T6594	BOLT-SOCKET
4	6V3213	RING
4	985747	NUT THIN
4	986004	LOCKNUT
4	1082580	BEARING-SLEEVE
4	1119292	BEARING-SLEEVE
2	1329767	PIN AS.
4	1460852	ADJUSTER
2	1509627	PLUG-CAP
4	1534069	SEAL
2	1618559	PIN

ACTION REQUIRED

See the attached Rework Procedure

SERVICE CLAIM ALLOWANCES

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts (D/N)	Labor Hrs (Cost)	Parts	Labor Hrs	Parts (C/L)	Labor Hrs (Sell)
0-5000 hrs	100 %	8.0	0	0	0	0
NOTE: This is an 8-hour job. However, if the existing pins and bearings are seized, up to an additional 8 hours removal labor may be claimed.(Claim maximum is 16 hours per tractor.) A detailed explanation/ justification must be included in the Claim Story.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

REWORK PROCEDURE

References:

Disassembly and Assembly (Challenger 35, Challenger 45 and Challenger 55 Agricultural Tractors Power Train) Service Manual Module; Form No: RENR1789.

Disassembly and Assembly (Challenger 35, 45 and 55 Agricultural Tractors Power Train) Service Manual Module; Form No: SENR8308-01.

Complete the following steps for each side of undercarriage:

1) Remove the belt.

2) Remove the inner idler.

3) Remove the swing link assembly.

4) Remove the front idler adjusting lever and cap assembly.

5) Replace the existing adjusting lever and cap components with the new parts as shown in Illustration 1. 6) Reinstall the adjusting lever and cap assembly. 7) Replace the existing tension cylinder rod bearing and seals as shown in Illustration 2. The bearing and cavity should be packed with lubricant (Water and Temperature Resistant Grease NLGI Grade 2 -- Reference Part No: 1291948) before the new seals are installed.

8) Reinstall the swing link assembly using the new 1329767 Pin As. (Retaining hardware is reused.)

9) Reinstall the inner idler.

10) Reinstall the belt.

11) Realign the belt using the adjustment lever. Lock the lever adjusters as described in the Installation Notes.

Illustration 1. Portion of the 1438660 Front Idler Group. Parts Listing below indicates the parts to be replaced on the existing swing link adjusting lever.

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Parts Required
Item	Part Number	Description	Qty (Per Lever)
1	8T6594	Bolt (Pin Setscrew)	2
2	1618559	Pin	1
3	6V3213	Ring	2
4	1460852	Adjuster (Alignment)	2
5	0986004	Jam Nut (M20)	2
6	0985747	Hex Nut (Thin)	2
7	1082580	Bearing	2
8	1119292	Bearing	2
9	1509627	Plug	1

Installation Notes:
1) The flat on the pin (Item 2 - Arrows B) should face toward the front of the tractor.

2) Tighten Bolt (Pin Setcrew - Item 1) and Hex Nut (Item 6) to 150 +/- 15 Nm (110 +/- 11 lb-ft).

3) Install bearings (Item 7) and Plug (Item 9) using 4C9506 Retaining Compound as directed.

4) After lever adjusting (belt alignment) is complete, apply Anti-Seize Compound (Part No: 4C5590) to Alignment Adjuster (Item 4). Tighten adjuster to 55 +/- 10 Nm (41 +/- 7 lb-ft).

5) Tighten Jam Nut (Item 5) to 160 +/- 15 Nm (120 +/- 11 lb-ft).

Illustration 2. Cross-section end view of tension cylinder rod with swing link (in phantom) and pin assembly. Parts Listing below indicates the parts to be replaced.

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