PRODUCT SUPPORT PROGRAM FOR REWORKING HARDWARE INTERNAL TO THE HYDRAULIC TANK ON CERTAIN D6 TRACK-TYPE TRACTORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING HARDWARE INTERNAL TO THE HYDRAULIC TANK ON CERTAIN D6 TRACK-TYPE TRACTORS [UEBE1046]

HYDRAULIC SYSTEM

TANK GP

PRODUCT SUPPORT PROGRAM FOR REWORKING HARDWARE INTERNAL TO THE HYDRAULIC TANK ON CERTAIN D6 TRACK-TYPE TRACTORS

UEBE1046-00

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23Sep2020

U-562

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING HARDWARE INTERNAL TO THE HYDRAULIC TANK ON CERTAIN D6 TRACK-TYPE TRACTORS
5056		PS46859

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NOTE:

AVSpare’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 AVSpare.

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 "PS46859" 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 AVSpare product analyst.

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TERMINATION DATE

30Sep2022

PROBLEM

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The hydraulic tank internal hardware needs to be reworked/replaced on certain D6 Track-Type Tractors. The existing hardware inside the tank may not have been tightened to the correct torque and might be introduced into the suction side of the hydraulic system and cause significant damage to the pumps and other components.

AFFECTED PRODUCT

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Model	Identification Number
D6	HNK00359-00360, 362-363, 370, 377-380, 382-383, 385-388, 398-399, 403, 406 RBP00378, 381, 383, 386-387, 389, 392-393, 395, 397, 399-400, 402, 405-409, 413
D6 LGP	KEW00382, 401, 410, 415 KMT00355-00356, 363, 365, 371, 374, 379-383, 385, 387-389, 393-394 KTW00351, 353-354, 357, 365, 367-372, 374 RDC00529, 531-533, 535, 537, 540-542, 545-546, 550, 554-556, 558-559, 561-562, 571-572, 578-579, 582, 584, 588, 590-591, 593, 596, 598, 604-606, 609-615, 617, 620, 623-627, 629, 631, 633-636, 639, 642, 644-645, 647, 650, 653-667, 669-675, 677-679, 681-682, 684, 686-687, 689-691, 693-695, 698-702, 704-705, 709-710
D6 XE	D5M00313-00319 HZL00312, 316, 318-319, 321-322, 324-328
D6 XE LGP	B7200312, 315-316, 318-320, 322, 324-326, 335-337 ES900320-00321, 329-330 HMH00375-00376, 384, 398-399, 405, 408-410, 417, 421, 423, 425, 427-429, 431, 433, 436-441, 443-447, 451-455, 458, 461-465, 467, 472-477, 485, 487-489, 493, 495, 497, 499, 502, 504, 506, 509-510, 512, 514, 517 LNC00331-00332, 335, 337, 340-344, 346, 352-354, 356, 361, 366-367, 369

PARTS NEEDED

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Qty	Part Number	Description
6	6V5839	WASHER-HARD
6	6V7732	BOLT-HEX HEAD
3	8T4219	STUD-WELD
1	2391139	SEAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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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If a machine has 200 hours or less, perform the steps in the attached rework procedure to inspect for missing or loose hardware inside the hydraulic tank.? If a machine has greater than 200 hours and has not experienced any unusual implement functions (loss of or intermittent function, slow, or drifting cylinders), a physical inspection of the hardware is not needed or recommended, since the successful 200+ hour accumulation on the machine is considered a reliable alternative for physical inspection.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-200 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.0-hour job
Note: Reasonable travel time and mileage will be allowed. NOTE: An extra hour is allowed for machines with fuel tank guards. NOTE: A maximum allowance for system cleanup reimbursement is $15,000 US dollars which represents 100.0 hours per machine.

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PARTS DISPOSITION

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

Rework Procedure

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1. Drain hydraulic oil via the ecology drain on the bottom side of the right hand fender into an appropriate container to allow oil recovery. Oil volume will be approximately 60 liters [15.8 gallons].

Image1.1.1

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2. For machines equipped with fuel tank guards, remove the right side guard. The weight of the guard is approximately 35kg [77lb].

Image1.2.1

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3. Remove the hydraulic enclosure to provide open access to the front of the tank.

Image1.3.1

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4. Disconnect outboard 554-1819 Hose from the charge filter adapter. Remove the inboard 554-1821 Hose between the filter and the accumulator block. Cap the hoses and ports.

Image1.4.1

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5. Remove the charge accumulator to gain access to the front tank cover. Place a plug in the accumulator port to prevent debris ingress during tank rework.

Image1.5.1

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6. Apply penetrating oil to the studs securing the front cover to ease nut removal. DO NOT USE IMPACT GUN. Once oil is activated, remove the 18 nuts and washers and set aside. Remove the cover and set aside taking care to prevent debris accumulation on the internal side of the cover.

**NOTE** Weld studs have exhibited failures with use of an impact gun. Take care in removal and subsequent re-torquing to not break the stud as this will cause significant tank/stud rework. If an impact gun was utilized, inspection of the stud welds are required. Utilizing an inspection mirror, view the stud welds inside the tank. Ensure the welds are not cracked.

Image1.6.1

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7. Remove the hardware securing the internal tank baffle. The 3 bolts and 3 washers will not be re-used. Set baffle aside taking care to prevent debris accumulation.

Image1.7.1

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8. Remove the hardware securing the forward screen. Discard 3 bolts and 3 washers. Set screen aside taking care to prevent debris accumulation.

Image1.8.1

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9. Confirm that 3 sets of hardware are securing the rear screen. Using a torque wrench apply 28Nm +/- 7Nm [20.7 ft-lb +/- 5.2 ft-lb] to the three joints securing the rear screen.

*Note: Because the joint contains a mechanical lock nut 0, 1, or 2 washers are allowed per joint

Image1.9.1

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10. Using 3 new 6V-7732 Bolts and 3 new 6V-5839 Washers reinstall the 6E-1752 Screen. Take care of wrench location during final tightening. Close proximity of neighboring components makes it possible to bottom the wrench out. Using torque wrench apply 30Nm +/- 7Nm [22.1 ft-lb +/- 5.2 ft-lb] to the three joints.

*This low torque is intentional and will be updated in service literature

Image1.10.1

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11. Confirm that 4 sets of hardware are securing the sight glass. Using a torque wrench, apply 30Nm +/- 5Nm [22.1 ft-lb +/- 3.7 ft-lb] to the four joints securing the sight glass.

Image1.11.1

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12. Using a magnet and/or an inspection mirror, sweep through the insides of the tank to confirm there is no extra/loose hardware or debris present in the tank.

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13. Using 3 new 6V-7732 Bolts and 3 new 6V-5839 Washers reinstall the baffle. Using torque wrench, apply 55Nm +/- 10Nm [40.6 ft-lb +/- 7.4 ft-lb] to the three joints.

*Tighten the baffle to the inboard boss first to prevent any joint gaps followed by the two slotted joints.

Image1.13.1

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14. Using a magnet and/or an inspection mirror, sweep through the insides of the tank to confirm there is no extra/loose hardware or debris present in the tank.

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15. Replace the front cover 239-1139 Seal. Reinstall the front 503-8264 Cover with original 18 8T-4121 Washers and 18 344-5675 Nuts. Snug all joints then using torque wrench, apply 40Nm +/- 7Nm [29.5 ft-lb +/- 5.2 ft-lb] to the 18 joints in the pattern shown in Image 1.16.1.

DO NOT USE AN IMPACT GUN

**NOTE** Weld studs have exhibited failures if not torqued as specified. Take care in removal and subsequent re-torquing to not break the stud as this will cause significant tank/stud rework. If an impact gun was utilized or anything unusual is noted when wrench torquing the studs, inspection of the welds are required. Utilizing an inspection mirror view the stud welds inside the tank. Ensure the welds are not cracked.

Image1.15.1

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16. Three weld studs have been provided in the event damage occurs. The original stud is projection welded from the inside of the tank and is welded 360 degrees around the flange on the stud. The internal head must remain in place to prevent weld blowout inside the tank. If the head is missing or significantly damaged, it is recommended to replace with a new tank.

Weld Rework Procedure

A. Cover the tank opening and adjacent components to prevent contamination. All work will be performed on the outside of the tank.

B. Clean area to remove oil

C. Grind the original stud to be slightly below flush with the outside of the tank. Weld in the voids 360 degrees around the original stud with weld material and grind flush. This will fill any potential leak paths that may have been opened up by damage to the original stud.

D. Secure the cover in place to mark the location of the center of the new stud.

E. Remove cover and weld new 8T-4219 Stud in place while holding perpendicular to tank. The weld size must not exceed 3mm and a stud weld gun is recommended for best results.

F. Verify that the weld material does not interfere with the 17mm diameter counterbore on the 503-8264 Cover. The cover must sit flush to ensure proper seal compression. Remove excess weld material as needed.

G. Reassemble and re-tighten to the proper torque as described in Step 15

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17. Review the accumulator 3D-2824 O-ring for damage or debris accumulation. As needed replace the seal. Reinstall the accumulator and tighten to a torque of 110Nm +/- 16Nm [81.1 ft-lb +/- 11.8 ft-lb].

Image1.17.1

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18. Review the adapter 6V-9746 O-rings for damage or debris accumulation. As needed replace the seals. Using a backup wrench on the adapters and a torque wrench, reinstall the 554-1821 Hose between the charge filter and the accumulator block applying 140Nm +/- 21Nm [103.3 ft-lb +/- 15.5 ft-lb]. Reinstall the 554-1819 Hose at the charge filter applying 140Nm +/- 21Nm [103.3 ft-lb +/- 15.5 ft-lb].

Image1.18.1

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19. Confirm the drain plug is tightened to a torque of 68 Nm +/- 7Nm [50.2 ft-lb +/- 5.2 ft-lb]. Fill the hydraulic tank with recovered oil. Warm up hydraulic system and check for leaks.

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20. Reinstall the hydraulic enclosure. Tighten to a torque of 55Nm +/- 10Nm [40.6 ft-lb +/- 7.4 ft-lb].

Image1.20.1

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21. For equipped machines, reinstall the right hand fuel tank guard. Tighten to a torque of 100 Nm +/- 20Nm [73.8 ft-lb +/- 14.8 ft-lb].

Image1.21.1

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22. If any hardware was identified as missing from Steps 7, 8, 9, or 11 OR any weld studs were repaired, we request the information be summitted through CPI Feedback within the Service Information Management System (SIMSi). Include the following information:
- Machine Serial Number
- Machine Hours
- Repair Date
- Location of missing hardware
- Location where hardware/debris found
- Summary of cleanout
- Number of weld studs repaired
Give the information to your Dealer Technical Communicator (TC) along with this service letter program number and CPI Number 465722.
Request the Dealer TC to submit the CPI Feedback.