PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H LGP, D5H LGP, AND D6H LGP TRACTORS - PS0394 - MAILED CACO
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PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H LGP, D5H LGP, AND D6H LGP TRACTORS - PS0394 - MAILED CACO
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.
A-138 4169, 4175 PS0394 NOTE: This Program can only be administered when a failure occurs, after the stated warranty period. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0394" as Part Number, "7755" as Group Number, "96" as Description Code, and the Track Serial Number in the 20 spaces of the Findings/Comments.
Termination Date
November 30, 1991
Problem
The tracks on certain D4H LGP, D5H LGP, and D6H LGP Tractors may develop dry joints at or before time to turn the bushings. Caterpillar will participate to assure acceptable track joint performance within the guidelines described below. The participation will be on a "One Time Only" basis for each track chain. This Program is intended to address dealer and user concerns for failures on machines operating in normal LGP applications, equipped with the proper track shoes, low impact underfoot conditions, and not being abused. This Program excludes all D4H and D5H Custom Skidders which are not equipped with quad link track.
Affected Product
Model Identification Number D4H LGP 9DB1-up 3AC1-Up D5H LGP 1DD1-Up 4KD1-Up 9HC1-Up 2SD1-Up D6H LGP 6FC1-Up 8YC1-Up 2TG1-Up 1KD1-Up 3YG1-Up 5HF1-Up 4GG1-Up 8FC1-Up PARTICIPATION EXCLUSIONS This Program does not apply to repairs completed during the stated warranty period. Such failures should be treated as machine or replacement parts warranty, and this Program should not be used. Field repairs are not a part of this Program because field repairs are usually made at low hours, limited to 1 or 2 joints, and occur during the normal warranty period. No participation will be considered by Caterpillar unless the track chain is permanently marked for identification and inspected according to the attached sheet. The track chain serial number must be included in the failure summary section of each claim. A fully completed copy of the inspection form must be submitted with the claim. The dealer should retain the original copy for future reference in the event Caterpillar requests additional information. MARKING PROCEDURE No participation will be considered by Caterpillar unless, at the first repair, a permanent serial number uniquely identifying the track is stamped or welded on the second full right-hand link from the pin end of the master link. Dealer may use any numbering system up to eight characters to identify the track. For example, KEMCL100 or KC1. See the Illustration. If possible, dealers should use the factory serial number stamped on the second full right-hand link from the pin end of the master link. Caterpillar prefers this number since it identifies a production date of the track. The serial number must be included in the Findings/Comments section of each claim. ****** IMAGE: SEBE4169.00001.001 CAPTION: LIMITS OF PARTICIPATION 1. 4,000 hours of operation or two years, whichever comes first. 2. 100% link and/or bushing wear. 3. One claim per tractor, only with crescent seal link assemblies. D4H LGP 9W4070 3T3885 D5H LGP 9W4074 9W4075 9W4185 9W9946 6Y3594 D6H LGP 9W4079 9W4080 9W9945 6Y1632 4. 67% participation on specified parts at the bushing turn.* 5. 67% participation on specified parts and 50% participation on labor where bushings are not turned.** * At bushing turn, no participation for labor, rubber stoppers, or plastic plugs will be considered. These are normal customer expense at bushing turn. Participation for parts will include new pins, bushings, thrust rings, and seal assemblies on dry joints. Links should be reused. ** Participation for parts will include new pins, bushings, seal assemblies, thrust rings, stoppers, and plugs. Links should be reused. Labor will include track disassembly and assembly only. REPAIR CONDITION CRITERIA Dealer must select one of two repair conditions according to the following criteria: Condition 1 - Bushing to link wear ratio determines the bushings will be turned. In most cases, the tractor will run to the bushing turn before pitch extension reaches the 6 mm (.25") limit. In some cases where pitch extension is approaching the limit, bushings may require turning early. This will avoid link counterbore damage and allow links to be reused. Condition 2 - The bushing to link wear ratio determines the track will not be turned and there are three or more dry joints exceeding 6 mm (.25") pitch extension.
Action Required
Condition 1 - Repair dry joints in dealer's track shop at the bushing turn. Refer to Undercarriage Reconditioning Bulletin SEBF8557 for proper repair procedure. Use Guidelines For Undercarriage Parts Reusability SEBF8558 to determine the necessary parts to replace. In most cases, link counterbores should be cleaned up and links reused. For the D6H only, new bushings must be used with the new rigid seals. Condition 2 - Completely disassemble entire track and replace necessary parts at the dealer track shop. In most cases, dry joints will be found in addition to those exceeding the 6 mm (.25") pitch extension. Use the Undercarriage Reconditioning Bulletin SEBF8557 for proper repair procedure. Use Guidelines For Undercarriage Parts Reusability SEBF8558 to determine necessary parts to replace. In most cases, link counterbores should be cleaned up and links reused. For the D6H only, new bushings must be used with the new rigid seals.
Parts Needed
- use as required D4H LGP Tractors 9K8550 Pin 9G8588 Bushing 3T5634 Seal Assembly 9G8591 Thrust Ring 6Y3879 Bushing & Seal Group* 6Y0473 Plug 9G1642 Stopper D5H LGP Tractors 3P3880 Pin 9G3105 Straight Wall Bushing or 6Y0929 Stepped Bushing 3T5631 Seal Assembly 9G3106 Thrust Ring 6Y0473 Plug 9G1642 Stopper 6Y3880 Stepped Bushing & Seal Group* D6H LGP Tractors 3P1108 Pin 9G8734 Straight Wall Bushing or 6Y0930 Stepped Bushing 6Y6473 Rigid Seal Assembly** 9G8726 Thrust Ring 6Y0473 Plug 9G1642 Stopper 6Y5406 Stepped Bushing & Seal Group* * Use instead of separate bushings and seals when forty percent or more of the joints are dry in each track. No D5H LGP/D6H LGP straight wall bushing and seal groups are available for earlier straight wall bushing track. Separate bushing replacement parts will be required for these tractors. ** Will retrofit into the current 9G8735/9G8736 or 9G8737/9G8738 Track Links. Do not use 6Y6473 Rigid Seal Assemblies with worn bushings. New bushings must be used with the rigid seal assemblies.
Service Claim Allowances
List on the claim only those new parts needed to make the repair authorized in the service letter. The track serial number as previously described in the Participation Exclusion Section of this service letter must be included in the comment section on each claim submitted. Dealer must retain a completed copy of the attached inspection form for each claim. No participation in this Program will be possible without this inspection data which must be completely filled out. Caterpillar Dealer Suggested Customer Suggested Condition Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. No. (D/N) (Cost) (C/L) (Sell) 1 100% 0 0% -- 0* 0* 2 100% D4H-8 0% D4H-8 0 0 D5H-8 D5H-8 D6H-11 D6H-11 * Under Condition 1 at bushing turn, no participation for rubber stoppers or plastic plugs will be considered. They are considered normal customer expense at the bushing turn. DRY JOINT DETECTION The only positive means of determining whether a dry track joint has developed is when pitch extension occurs. Hot, squeaking, and/or kinking joints are only indicators of potential dry joints. If dry joints develop on H-Series tractors, pitch will usually extend at a much slower rate than larger elevated sprocket tractors. Therefore, the possibility of running to a bushing turn or link wear-out before the pitch extension reaches 6 mm (.25") is quite good. In some cases where pitch extension is approaching the limit, bushings may require turning early. This will avoid probable link counterbore damage and allow links to be reused. On Condition #2, track removal should be based upon pitch extension of 6 mm (.25") on a minimum of three dry joints.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. ATTACH (1-Track Inspection Form) TRACK INSPECTION FORM A) DEALER CODE ............... H) EMPLOYEE ID ................ B) DATE (MMDDYY) ............. I) PART NO. RESPONSIBLE ....... C) CUSTOMER .................. J) QUANTITY ................... D) MODEL ..................... K) DESCRIPTION CODE ........... E) SERIAL NO. ................ K) GROUP NO. .................. F) MACH HOURS ................ L) INOPERABLE CODE ............ G) WORK ORDER NO. ............ TRACK NO. ............ TRACK HOURS ............ PPR ............ LINK PART NO. ............ SHOP OR FIELD REPAIR? ............ BRAND OTHER THAN CAT ............ TURNED ? YES / NO MEASUREMENTS DIMENSION % WORN LINK .............!...... SHOE WIDTH ..................... BUSHING ..........!...... SCALE ............!...... REGROUSERED? YES / NO SHOE .............!...... NUMBER OF: (BEFORE DISASSEMBLY) (AFTER DISASSEMBLY) DRY JOINTS ............... BORE DAMAGED LINKS ........... LOW JOINTS ............... PINS GALLED .................. CRACKED LINKS ............ BROKEN PINS .................. CRACKED SHOES ............ CRACKED BUSHINGS .............BUSHINGS WALKING ......... GROVED BUSHINGS .............. DAMAGED SPLIT LINKS? YES / NO PART NUMBER OF SEAL REMOVED ............. REPAIR OPTIONS A. FLOOR REPAIR C. REGROUSER B. TURN PINS & BUSHINGS D. SCRAP-NO WARRANTY REASON TRACK WAS REMOVED ...................................... COMMENTS: ..................................................... ............................................................... ............................................................... ............................................................... ............................................................... ...............................................................
Caterpillar Information System:
PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H, D5H, AND D6H TRACTORS - PS0395 - MAILED CACO PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H, D5H, AND D6H TRACTORS - PS0395 - MAILED CACO
PSP FOR REPLACING THE REAR GEAR TRAIN ON CERTAIN D11N TRACTORS AND 3508 ENGINES (SPARE) - PS0410 - MAILED US AND CANADA, COFA COS A, LIMITED CACO - SEE SUPPLEMENT SEBE4196 DATED JANUARY 6, 1990 PSP FOR REPLACING THE REAR GEAR TRAIN ON CERTAIN D11N TRACTORS AND 3508 ENGINES (SPARE) - PS0410 - MAILED US AND CANADA, COFA COS A, LIMITED CACO - SEE SUPPLEMENT SEBE4196 DATED JANUARY 6, 1990
PSP FOR ERRATIC OR INTERMITTENT SHIFTING OF THE ICM CONTROLLED TRANSMISSIONS ON CERTAIN 621E, 623E, 627E, 631E, 637E, 651E, AND 657E SCRAPERS; 768C, 772B, AND 776B TRACTORS; AND 769C, 773B, 777B, 785, AND 789 TRUCKS - PS4402 - MAILED US AND CANADA , PSP FOR ERRATIC OR INTERMITTENT SHIFTING OF THE ICM CONTROLLED TRANSMISSIONS ON CERTAIN 621E, 623E, 627E, 631E, 637E, 651E, AND 657E SCRAPERS; 768C, 772B, AND 776B TRACTORS; AND 769C, 773B, 777B, 785, AND 789 TRUCKS - PS4402 - MAILED US AND CANADA ,
Product Support Program For Repeat Track Joint Failures (Leaks) On D11N Tractors Product Support Program For Repeat Track Joint Failures (Leaks) On D11N Tractors
PSP FOR INSTALLING A NEW DRIVE SHAFT SLIP JOINT GROUP, SPIDER, AND SHAFT ASSEMBLIES IN CERTAIN 518 SKIDDERS AND 518 GRAPPLE SKI DDERS - PS4372 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR INSTALLING A NEW DRIVE SHAFT SLIP JOINT GROUP, SPIDER, AND SHAFT ASSEMBLIES IN CERTAIN 518 SKIDDERS AND 518 GRAPPLE SKI DDERS - PS4372 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, PARTS STOCK ACTION ONLY - BOLTS AND WASHERS THAT WERE USED TO HOLD THE COUNTERWEIGHT ON THE CRANKSHAFT IN SOME OF THE 3500 SER IES FAMILY OF ENGINES NEED TO BE REMOVED FROM PARTS STOCK - PI7215 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA,
PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA PARTS STOCK ACTION ONLY - CERTAIN ELECTRIC STARTING MOTORS USED ON THE 3100 SERIES FAMILY OF ENGINES NEED TO BE REMOVED FRO M PARTS STOCK - PI7218 - MAILED US AND CANADA
PSP FOR REINFORCING THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4389 - MAILED US AND CANADA, COFA, BRAZIL, CFE L, COSA, LIMITED CACO PSP FOR REINFORCING THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4389 - MAILED US AND CANADA, COFA, BRAZIL, CFE L, COSA, LIMITED CACO
PSP FOR REINFORCING THE FUEL TANK ON CERTAIN 623E SCRAPERS - PS4387 - MAILED US AND CANADA, COFA, COSA, LIMITED CACO PSP FOR REINFORCING THE FUEL TANK ON CERTAIN 623E SCRAPERS - PS4387 - MAILED US AND CANADA, COFA, COSA, LIMITED CACO
PSP FOR WINCH CLUTCH LOCK-UP ON CERTAIN D6H TRACTORS USED IN LOGGING AND PIPELINE APPLICATIONS - PS4363 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA PSP FOR WINCH CLUTCH LOCK-UP ON CERTAIN D6H TRACTORS USED IN LOGGING AND PIPELINE APPLICATIONS - PS4363 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA
PSP FOR UPDATING THE DROPBOX ON CERTAIN 657E SCRAPERS - PS4384 - MAILED US, CANADA, CACO, COFA, COSA PSP FOR UPDATING THE DROPBOX ON CERTAIN 657E SCRAPERS - PS4384 - MAILED US, CANADA, CACO, COFA, COSA
PSP FOR REPAIRING CRACKS IN THE REAR OF THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4377 MAILED US, CANADA, CACO, BR AZIL, CFEL, COSA PSP FOR REPAIRING CRACKS IN THE REAR OF THE EJECTOR ON CERTAIN 621E, 621S, AND 627E SCRAPERS - PS4377 MAILED US, CANADA, CACO, BR AZIL, CFEL, COSA
PRIORITY - THE LEFT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3436 - MAILED US, CAN ADA PRIORITY - THE LEFT HAND AXLE SHAFT NEEDS TO BE REPLACED ON CERTAIN 651E AND 657E WHEEL TRACTORS - PI3436 - MAILED US, CAN ADA
PSP FOR INSTALLING A NEW CAMSHAFT AND LIFTERS IN CERTAIN D11N TRACTORS; 776B TRACTORS; AND 777B, 785 AND 789 TRUCKS - PS0423 - M AILED US AND CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL - NOTE:THIS PROGRAM CANCELED AND REPLACED BY JULY 31, 1990 SL PSP FOR INSTALLING A NEW CAMSHAFT AND LIFTERS IN CERTAIN D11N TRACTORS; 776B TRACTORS; AND 777B, 785 AND 789 TRUCKS - PS0423 - M AILED US AND CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL - NOTE:THIS PROGRAM CANCELED AND REPLACED BY JULY 31, 1990 SL
PRIORITY - NEW FIRE SUPPRESSION CONTROL NEEDS TO BE INSTALLED ON CERTAIN D8N, D9N, D10N, AND D11N TRACTORS; AND 992C LOADERS - P I3435 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA PRIORITY - NEW FIRE SUPPRESSION CONTROL NEEDS TO BE INSTALLED ON CERTAIN D8N, D9N, D10N, AND D11N TRACTORS; AND 992C LOADERS - P I3435 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA
PSP FOR INCREASING THE WELD ON THE TRANSMISSION TUBE ASSEMBLIES (SLIDE TRACKS), AND INSTALLING BEVEL GEAR, BEVEL GEA R SHAFT BEARING, AND RETAINING BOLTS ON CERTAIN D10N TRACTORS - PS4390 - MAILED US AND CANADA, CACO, CFEL, COSA PSP FOR INCREASING THE WELD ON THE TRANSMISSION TUBE ASSEMBLIES (SLIDE TRACKS), AND INSTALLING BEVEL GEAR, BEVEL GEA R SHAFT BEARING, AND RETAINING BOLTS ON CERTAIN D10N TRACTORS - PS4390 - MAILED US AND CANADA, CACO, CFEL, COSA
PSP FOR INSTALLING THERMOCOUPLES TO MONITOR EXHAUST GAS TEMPERATURES ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785 , AND 789 TRUCKS - PS4399 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA PSP FOR INSTALLING THERMOCOUPLES TO MONITOR EXHAUST GAS TEMPERATURES ON CERTAIN D11N TRACTORS; 776B TRACTORS; 777B, 785 , AND 789 TRUCKS - PS4399 - MAILED US AND CANADA, CACO, COFA, CFEL, COSA
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PARTS STOCK ACTION ONLY:9J0942 PIN ASSEMBLIES IN PARTS STOCK NEED TO BE CHECKED FOR CORRECT LENGTH - PI7227 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY:9J0942 PIN ASSEMBLIES IN PARTS STOCK NEED TO BE CHECKED FOR CORRECT LENGTH - PI7227 - MAILED US AND CAN ADA, CACO, COFA, BRAZIL, CFEL, COSA
Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders Supplemental Steering Flow Switch Needs To Be Replaced On Certain 992C Loaders
PSP FOR INSTALLING NEW BUCKET TIP ADAPTER ON CERTAIN 235B/C EXCAVATORS AND 988B LOADERS - PS0406 - MAILED US AND CANADA, CFE L, COSA, LIMITED CACO PSP FOR INSTALLING NEW BUCKET TIP ADAPTER ON CERTAIN 235B/C EXCAVATORS AND 988B LOADERS - PS0406 - MAILED US AND CANADA, CFE L, COSA, LIMITED CACO
PSP FOR REPEAT TRACK JOINT FAILURES (LEAKS) ON D8N TRACTORS - PS0430 - MAILED COFA, CFEL, COSA PSP FOR REPEAT TRACK JOINT FAILURES (LEAKS) ON D8N TRACTORS - PS0430 - MAILED COFA, CFEL, COSA
PSP FOR PISTON FAILURES ON D11N TRACTORS; 776B TRACTORS; AND 777B, 785, AND 789 TRUCKS - PS0424 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA PSP FOR PISTON FAILURES ON D11N TRACTORS; 776B TRACTORS; AND 777B, 785, AND 789 TRUCKS - PS0424 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA
SERVICE LETTER SUPPLEMENT FOR DECEMBER 1, 1989 SL - PSP FOR INSTALLING A NEW CAMSHAFT & LIFTERS IN CERTAIN D11N TRACTORS; 776 B TRACTORS; & 777B, 785 & 789 TRUCKS - PS0423 - MAILED US & CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL SERVICE LETTER SUPPLEMENT FOR DECEMBER 1, 1989 SL - PSP FOR INSTALLING A NEW CAMSHAFT & LIFTERS IN CERTAIN D11N TRACTORS; 776 B TRACTORS; & 777B, 785 & 789 TRUCKS - PS0423 - MAILED US & CANADA, CACO, COFA, BRAZIL, COSA, LIMITED CFEL