PSP FOR TRACK JOINT FAILURES (LEAKS) ON D4H LGP, D5H LGP, AND D6H LGP TRACTORS - PS0394 - MAILED CACO Caterpillar

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.

November 30, 1991

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.

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.

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.

 - 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.

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.

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: .....................................................
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