PRODUCT SUPPORT PROGRAM FOR REPLACING OR UPDATING THE 240-9478 REAR HOOD ASSEMBLY ON CERTAIN 631G AND 637G WHEEL TRACTOR-SCRAPERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING OR UPDATING THE 240-9478 REAR HOOD ASSEMBLY ON CERTAIN 631G AND 637G WHEEL TRACTOR-SCRAPERS

Usage:

REBE2398-02

Show/hide table

28Sep2007

(Revised 22Feb2008)

U-495

A-406

D-397

O-428

Show/hide table

*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING OR UPDATING THE 240-9478 REAR HOOD ASSEMBLY ON CERTAIN 631G AND 637G WHEEL TRACTOR-SCRAPERS
7251		PS42526

Show/hide table

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 "PS42526" 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.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 28Sep2007 (Revised 12Dec2007) Service Letter. Changes have been made to the Parts Needed, Affected Product, and Rework Procedure.

Show/hide table

TERMINATION DATE

30Sep2009

PROBLEM

Show/hide table

The existing rear hood can crack on certain 631G and 637G Wheel Tractor-Scrapers. If the existing hood fails, it will not be able to withstand the given loads. Also, the existing rubber hood bumpers can fall out or degrade. If the existing hood bumpers fall out or degrade, wear can occur between the top door assembly and the rear hood assembly.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
631G	DFA00125-00128, 131-145, 147-153, 156-180, 182-205, 207-224
637G	DFJ00225, 227-231, 234-279

Show/hide table

*****Group 2*****
631G	DFA00225-00226, 228-229, 231-232, 234-236, 238, 240-241, 243-245, 247-249, 251-252, 254, 256-283, 285-303, 306-309, 311-312, 314-327
637G	DFJ00280-00283, 285-351

Show/hide table

*****Group 3*****
631G OEM	M1W00100-00101, 109
CIPI	0EM01616

Show/hide table

*****Group 4*****
631G OEM	M1W00102-00108, 110-117

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
1	4L6454	BOLT
4	4L9337	BOLT
1	5P1075	WASHER-HARD
3	5P2566	BOLT
2	5S7383	BOLT
2	8T4835	BOLT
127	1264214	SEAL (BULK)
6	1984777	WASHER-HARD
7	1984778	WASHER-HARD
1	3014214	HOOD AS - REAR
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*****Group 2*****
1	4L6454	BOLT
4	4L9337	BOLT
1	5P1075	WASHER-HARD
3	5P2566	BOLT
2	5S7383	BOLT
7	6C3680	RIVET-POP
2	8T4835	BOLT
1	1548874	KIT-ADHESIVE
6	1984777	WASHER-HARD
7	1984778	WASHER-HARD
8	2966677	BUMPER-WEAR
7	3001710	WASHER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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.
*****Group 3*****
1	4L6454	BOLT
4	4L9337	BOLT
1	5P1075	WASHER-HARD
3	5P2566	BOLT
2	5S7383	BOLT
2	8T4835	BOLT
127	1264214	SEAL (BULK)
6	1984777	WASHER-HARD
7	1984778	WASHER-HARD
1	3014214	HOOD AS - REAR
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*****Group 4*****
1	4L6454	BOLT
4	4L9337	BOLT
1	5P1075	WASHER-HARD
3	5P2566	BOLT
2	5S7383	BOLT
7	6C3680	RIVET-POP
2	8T4835	BOLT
1	1548874	KIT-ADHESIVE
6	1984777	WASHER-HARD
7	1984778	WASHER-HARD
8	2966677	BUMPER-WEAR
7	3001710	WASHER
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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

Show/hide table

Refer to the attached Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
*****Group 1*****
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
5001-7500 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 3.0-hour job for Group 1

Show/hide table

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%
*****Group 2*****
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
5001-7500 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 2

Show/hide table

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%
*****Group 3*****
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
5001-7500 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 3.0-hour job for Group 3

Show/hide table

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%
*****Group 4*****
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
5001-7500 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 4

PARTS DISPOSITION

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

Rework Procedure

Group Number 1 Group Number 3

Refer to the Service Manual as necessary.

Removal
1. Remove handrail assembly (1) and save for reuse. The hardware will not be reused. Make sure the handrail has lower gusset plates.

Image1.1.1

2. Remove bolts (2) and save for reuse. Loosen bolts (3) so that side access door (4) is adjustable.

Image1.2.1

Image1.2.2

3. Loosen clamp (6) and remove exhaust pipe (5) and save for reuse. (OPTIONAL)

Image1.3.1

4. Attach Tooling (A) (138-7533 Link Bracket) and a suitable lifting device to rear hood (7). The weight of rear hood (7) is approximately 82 kg (180 lb).

Image1.4.1

5. Remove bolts (8), (9), and (10). The bolts will not be reused. Remove rear hood (7).

Image1.5.1

Image1.5.2

6. Remove plate (11) and hardware (12) from rear hood. Save plate and hardware for reuse. The rear hood will not be reused.

Image1.6.1

Installation
1. Replace lower hardware (14) on Y-brace (13). NOTE: Use double washers on same side of bolt head.

Image1.7.1

2. Attach Tooling (A) and a suitable lifting device to rear hood (11). The weight of rear hood (7) is approximately 82 kg (180 lb). Position rear hood (7) on the machine.

Image1.8.1

3. Attach Y-brace (13) to rear hood (7) using new hardware according to Image 1.9.1.

Image1.9.1

4. Attach rear hood (7) using new hardware according to Image 1.10.1. Drill (21/64") and tap (3/8"-16 NC thread) for second hole between gussets at right rear corner of hood.

Image1.10.1

5. Position exhaust pipe (5) and tighten clamp (6).

Image1.11.1

6. Position door assembly (4) and install bolts (2). Tighten bolts (3) on door assembly (4).

Image1.12.1

Image1.12.2

7. Install plate (11) and associated hardware (12) into deck assembly.

Image1.13.1

8. Install P-handle (1) on rear deck (7) using new hardware according to Image 1.14.1 Reference Media Number REBE1555 to confirm that your machine has the most current 291-2983 P-Handle.

Image1.14.1

Group Number 2 Group Number 4

Refer to the Service Manual as necessary.

Remove/Install
1. Replace P-handle bolts and washers and right side rear deck hardware, one at a time, with new hardware.

Image2.1.1

Image2.1.2

2. With rear deck supported, at top of Y-support (13), replace bolts and washers, one at a time, with new hardware.
3. With rear deck supported, at bottom of Y-support (13), replace bolts and washers, one at a time, with new hardware. NOTE: Use double washers on same side of bolt head.

Image2.2.1

4. Use a stepped cone drill bit in order to enlarge existing 8 holes shown in image 2.3.1 to 25.4mm (1.0 in.).
5. Use 129-1063 Rivet Tool to install rivets, washers, and wear pads in 7 locations on rear hood assembly.
6. In 8th location, sand bonding surface of wear pad with rough sandpaper.
7. Clean bonding surfaces with a cleaning solvent.
8. Use epoxy to fasten last wear pad in the 8th location.