PUMP GP-GR 4 20R6492 - Caterpillar

Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPAIRINGTHE UPPER RADIATOR MOUNTS THAT MAY CRACK ON CERTAIN D3C III, D4C III, D5CIII TRACK TYPE TRACTORS AND 933C AND 939C TRACK TYPE LOADERS
7155 PS50211
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50211" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
April 30, 2003PROBLEM
The upper radiator mounts may crack on certainD3C III, D4C III, D5C III Track Type Tractors and 933C and 939C Track TypeLoaders. This failure can leave the cooling package unsupported at thetop allowing the hydraulic oil cooler to contact the cooling fan.AFFECTED PRODUCT
D3C III 5GS1-549
4KS1-756
4TS1-837D4C III 6BS1-559
4LS1-445
8CS1-950D5C III 5HS1-701
6CS1-676
7PS1-1084933C 4MS1-441
5JS1-366939C 6DS1-899PARTS NEEDED
2 - 8T3597 Nut - Weld
2 - Fabricated brackets There may be resultant damage in thisrework. If so, a new 1166562 Core Assembly - Oil and either a 1004367 ora 6I3505 Spider Assembly may be needed. Some D5 models require a 6I3505Spider Assembly instead of the 1004367 Spider Assembly. Early D5 models(Apr ~ Sep97) were built with 22" fans, later D5's have the same 21" fanas do all other models (D3 D4, 933C and 939C). Measure D5 spiders and orderaccordingly. The 6I3505 measures 559 mm (22 in.) tip to tip, the 1004367is 533 mm (21 in.).ACTION REQUIRED
See the attached rework procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-2500 / 0-48 mo 100% 9 0 0 0 0
2501-5000 /49-72 mo 33 1/3% 4.5 0 0 50% 4.50
This is a 9-hour job.Note: Some failed machines may have resultantdamage. If so, the 1165652 Core Assembly - Oil Cooler and 1004367 or 6I3505Fan replacement and an additional 4.0 hours of labor may be claimed underthis program. PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Remove the hood, both engine enclosure panels,radiator grill, and both upper radiator mounts. See Illustration 1.
Remove radiator guard.
Measure distances A and B from center of upperradiator mount weld nut to the side of the radiator guard. This measurementwill be used to locate the new bracket. See Illustration 2.
Remove both upper radiator mount brackets fromthe radiator guard. See Illustration 2.
Fabricate 2 brackets. See Illustration 4.
Weld 8T3597 Nuts to the brackets as shown in Illustration3.
Weld new bracket assemblies to the radiator guardusing the dimensions recorded in Step 3.
Install radiator guard tightening the lower mountingbolts to 100 +/-20 N.m (74 +/- 15 lb-ft).
Install upper radiator mount isolators and tighten2 bolts A to 100 +/- 20 N.m (74 +/- 15 lb-ft).
10. Install upper radiator mount cap andtighten 4 bolts B to 28 +/- 7 N.m (21 +/- 5 lb-ft).
ILLUSTRATION 1
ILLUSTRATION 2
ILLUSTRATION 3