PRODUCT SUPPORT PROGRAM FOR REPLACING PART OF THE ENGINE WATER LINES GROUP ON CERTAIN D7R II TRACK-TYPE TRACTORS AND 572R II PIPELAYERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING PART OF THE ENGINE WATER LINES GROUP ON CERTAIN D7R II TRACK-TYPE TRACTORS AND 572R II PIPELAYERS

Usage:

REBE2382-01

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05Sep2007

(Revised 10Sep2007)

U-432

A-358

O-380

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING PART OF THE ENGINE WATER LINES GROUP ON CERTAIN D7R II TRACK-TYPE TRACTORS AND 572R II PIPELAYERS
1380		PS42501

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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 "PS42501" 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 Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 05Sep2007 Service Letter. Changes have been made to the Parts Needed to reflect the proper length of bulk hose required.

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TERMINATION DATE

30Sep2009

PROBLEM

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The existing 266-0249 Coolant Hose can fail on certain D7R II Track-Type Tractors and 572R II Pipelayers. If the existing coolant hose fails it will result in a coolant leak.

AFFECTED PRODUCT

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Model	Identification Number
572R II	DSC00302-00319
D7R II	AEC01500-01644
D7R II LGP	ABJ01500-01539
D7R II XR	AGN01500-01622

PARTS NEEDED

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Qty	Part Number	Description
2	2V4868	FITTING
1	5P1465	HOSE-BULK (73.5 cm required for repair)
1	5P3422	TEE-PIPE
1	6V1820	BOLT
1	6V5839	WASHER-HARD
1	8T4983	CLAMP-BAND
4	8T4984	CLAMP-BAND
1	1637454	TUBE AS
1	1885071	HOSE
1	2093721	HOSE
1	2093722	HOSE

ACTION REQUIRED

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See the attached rework procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 6.0-hour job

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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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This procedure will remove the current 266-0249 one-piece coolant return hose and replace with hoses and tubes. Refer to the 163-4762 Water Lines Group and the 164-4444 Water tank Group for general information. A detailed rework procedure is given below.

1. Rework the hole in the 163-7454 Tube Clip into an oversized slot measuring 13.5 mm x 26 mm. This will allow the clip to align with the support bracket mounting hole. Image 1.1.1 shows the slot after the rework is completed.

Image1.1.1

2. Remove the front and center bottom guards in preparation to rework the coolant lines and drain the engine coolant.
3. Drain the engine coolant into a suitable container and plan to reuse at the end of this rework procedure.
4. Remove the left hand side lower 6Y-0123 Door Assembly. See Image 1.2.1 below.

Image1.2.1

5. If the machine is equipped with air conditioning, loosen the air conditioning belt. Also loosen the air conditioning compressor mounting bracket (185-1433) from the air cleaner support bracket.
NOTE: Keep all air conditioning lines attached. It is not necessary to disconnect any of the A/C lines during this update.
See Images 1.3.1, 1.3.2, and 1.3.3 below for more details.

Image1.3.1

Image1.3.2

Image1.3.3

6. Loosen all of the associated clamps on the 266-0249 coolant return hose and remove the hose from the machine. Save the 8T-4983 Clamp on the aftercooler outlet for reuse. See Images 1.4.1 and 1.4.2 below.

Image1.4.1

Image1.4.2

7. Insert the reworked 163-7454 Tube (from step 1) from the left hand side of the machine. See Image 1.5.1 below.

Image1.5.1

8. Loosely assemble 209-3721, 209-3722, and 188-5071 Hoses. See Images 1.6.1, 1.6.2, and 1.6.3 below.

Image1.6.1

Image1.6.2

Image1.6.3

9. Tighten the six hose clamps (4 of 8T-4984 and 2 of 8T-4983) to 70 +\- 15 Nm. The clamp locations are shown in Image 1.6.1 above. Attach the 163-7454 Tube to the 164-9885 Air Cleaner Support Bracket by using a 6V-1820 Bolt and 6V-5839 Washer through the reworked slot. Tighten to a torque of 55 +\- 10 Nm. Refer to Images 1.7.1 and 1.7.2.

Image1.7.1

Image1.7.2

10. Retighten the air conditioning bracket to the air cleaner bracket that was loosened in step 5.
11. Re-tension the air conditioning belt. The belt should deflect 14 to 20 mm (0.56 to 0.81 inch) under 110 N (25 lb) of force. Use a 144-0235 Belt Tension Gauge in order to measure the tension.
12. Install the 5P-3422 Tee-Pipe into 163-7454 Tube. Apply pipe thread sealant (reference 5P-3413) to the 5P-3422 Tee and install into the 163-7454 Tube as show in Image 1.8.1 below.

Image1.8.1

13. Apply pipe thread sealant to the 2V-4368 Fittings and install into the 5P-3422 Tee.
14. Reconnect vent hoses. Use the new 5P-1465 Hose (730 mm +/- 5 mm length) as shown in Image 1.9.1 below.

Image1.9.1

15. Refill the machine with coolant and run to test for leaks.
16. Reinstall the left hand side lower door assembly. Also reinstall the middle and front bottom guards.
17. Verify the coolant level and add as needed.