CARTRIDGE GP-A 20R2657 - Caterpillar

This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4813" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Although this Program is to be administered as described above on the Affected Product, parts should be removed from Parts Stock as soon as possible.
Termination Date
July 31, 2000Problem
Cracked intake manifolds need to be reworked on certain D3C III, D4C III, D5C III Track Type Tractor and 933 and 939 Track Type Loaders. The intake manifolds may crack with the 1260735 Muffler Support Bracket specified in PI3897. Additionally, manifold failures may occur where the air compressor bracket bolts to the manifold.
Affected Product
Model & Identification Number
D3C IIII (6SL1-2629, 7XL1-1201, 9TS1-248)
D4C III (6YL1-2024, 7SL1-706, 1FW1-288)
D5C III (9DL1-2283, 6ZL1-848, 8ZS1-234)
933 (8FL1-416, 9EL1-112)
939 (9GL1-677)
Parts Needed
1 - 4P7581 Clip5 - 5P4116 Washer - Conical1 - 3S2093 Strap - Cable3 - 8T3647 Bolt2 - 8T4121 Washer - Plate2 - 8T4189 Bolt1 - 8T4195 Bolt3 - 2W3484 Spacer1 - 1327551 Spacer1 - 1639101 Support AssemblyAction Required
See the attached Rework Procedure.
Parts Stock
Remove all 1260735 Muffler Support Brackets from Parts Stock.
Service Claim Allowances
This is a 2-hour job.
If the manifold is cracked and needs to be replaced, an additional 6 hours for labor will be allowed.
Parts Stock
Submit one claim for all 1260735 Muffler Support Brackets removed from Parts Stock.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
(1-Rework Procedure)Rework Procedure
1. Remove the 1260735 Muffler Support Bracket.2. Inspect the intake manifold adjacent to the old muffler support bracket for cracking of the pedestal mounting boss where the bracket was bolted onto the manifold.3. Remove the 1007059 Air Conditioning Compressor Support Bracket.4. Inspect the intake manifold adjacent to the Air Conditioning Compressor Support Bracket for cracking of the pedestal mounting boss where the bracket was bolted onto the manifold.5. In either case if the manifold is cracked, replace the 1078360 Manifold using a new 1073664 Gasket. The new support assembly and spacers will be mounted to three manifold mounting flanges to provide a more robust joint. The air conditioning compressor support assembly will be reworked to prevent future failures.
6. If necessary slot the rear holes in the air conditioning compressor support bracket to eliminate any misalignment between the bracket holes and intake holes. See Illustration 1.7. Reinstall the 1007059 Air Conditioning Compressor Support Bracket and compressor. See Illustration 2. The intake manifold is aluminum so it is important not to over tighten the bolts. Using a 9S7353 Torque Wrench or equivalent, tighten all bolts to 28 7 N m (21 5 lb-ft) following the sequence in Illustration 2.
8. Referring to Illustration 3, remove the M8 weld nut on the 1030664 Muffler Support Bracket.