Usage:
NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1406" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI1406" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
NOTE: This Revised Service Letter replaces the March 1, 1999 Service Letter. Changes have been made to all areas of the letter.
Problem
Some D8H tractors and all D8K Tractors equipped with two dozer lift cylinders have hydraulic hoses that run from a manifold on the crosstube in the engine compartment to each lift cylinder tube assembly. These hydraulic hoses can be damaged by rubbing on the bottom edge of the hood. Failure to replace damaged hoses can result in serious injury or death if one of these hoses bursts and sprays hot hydraulic oil onto hot engine parts and the operator.
Failure to properly maintain the bearings in the crosstube and the lift cylinder trunnion can lead to the hoses contacting the hood due to excessively worn bearings in the crosstube and trunnion. Lift cylinder hoses contacting the hood results in fraying and wearing of the hydraulic hoses. A frayed hose can be weakened as the hood wears into the steel reinforcement layers or as moisture causes the steel reinforcement to corrode. When a hose is sufficiently weakened, high pressure oil in the system can cause the hose to fail. High pressure oil can then spray onto hot parts of the engine and cause a fire resulting in serious injury or death.
Location of Parts
Affected Product
Model & Identification Number
D8H and D8K Track-type Tractors which are equipped with a bulldozer arrangement having two dozer lift cylinders and a hydraulic lift cylinder lines manifold on the crosstube in the engine compartment are affected.
Tractors listed below are affected provided that all of the following statements are true. If any of the following 4 statements is false, the tractor is not affected.
D8H (22A1-1564 35A134-776 36A122-5722 46A45-34086 52A1-84 68A1-5903 )
D8K (66V641-6328, 66V75172-75196, 66V76672-76676 76V381-1034 , 76V75172-75184, 76V75472 77V641-18848 , 77V75172-75433, 77V78072-78101, 77V78172-78175, 77V78178-78193, 77V78195)
Parts Needed
Dealers will need to order parts for this Program.
NOTE: Initially, some parts for this program are in short supply. Dealers should only order quantities that they will be using within 30 days. Dealers will not be able to return any unused parts.
D8H
Depending on how a particular tractor is configured, choose one of two D8H lift line kits and then determine if the 177-5006 Tube Assembly and 9X8873 Bolts are required for that tractor. (See Action Required)
- 1 - KIT-LIFT LINE (Either 170-5928 or 169-6533)
- 1 - 177-5006 TUBE ASSEMBLY (only if required)
- 5 - 9X8873 BOLTS (only if 177-5006 tube assembly required)
- 1 - 177-5006 TUBE ASSEMBLY (only if required)
Kit identification is made by viewing the lift cylinder hose connections to the manifold at the center of the crosstube. Tractors with hoses connected to the manifold with hose clamps use 170-5928 Lift Line Kit. Tractors with hoses connected to the manifold with split-flange type fittings use 169-6533 Lift Line Kit. (see Action Required)
- 177-5006 Tube Assembly and 9X8873 Bolts are required when the lift line tube assembly on the right hand lift cylinder mounts to the inside face of the quick drop valve. On most D8H Track-type Tractors the lift lines tube assembly mounts to the rear face of the quick drop valve. (See Action Required)
NOTE: Kit identification and tube assembly requirements can not be determined by tractor serial number. Use the following serial number ranges only as a general reference.
Tractors 22A1-1145, 35A134-776, 36A122-4468, 46A45-10724, 52A1-84, and 68A1-1002 have a higher probability of NOT being Affected Product due to not having a hydraulic lift cylinder lines manifold at the center of the crosstube.
Tractors 22A1146-1564, 36A4469-5200, 46A10725-21300, and 68A1003-3000 have a higher probability of requiring the 170-5928 Lift Lines Kit.
Tractors 36A5201-5722, 46A21301-34086, and 68A3001-5903 have a higher probability of requiring the 169-6533 Lift Lines Kit.
Tractors 22A1146-1260, 36A4469-4650, 46A10725-13000, and 68A1003-1300 have a higher probability of requiring the additional 177-5006 tube assembly and 9X8873 bolts.
D8K
- 1 - 168-4428 KIT-LIFT LINE
NOTE: Kit identification can be confirmed by viewing the manifold at the center of the crosstube and the lift line tube assembly on the lift cylinders. The hoses to the manifold mount with split-flange type connectors. The lift line tube assembly on both lift cylinders mounts to the inside face of the quick drop valve.
Action Required
Modify affected D8H and D8K Tractors to prevent the crosstube manifold to lift cylinder tube assembly hoses from rubbing on the bottom edge of the hood.
Determine whether a particular tractor is affected by this program. The serial number alone can not answer this question. A tractor is affected by this program provided that all of the following 4 statements are true for that tractor. If any of the following 4 statments is false, that particular tractor is not affected.
1. The tractor is equipped with a bulldozer.
2. The tractor is equipped with two dozer lift cylinders and has a hydraulic lift cylinder lines manifold at the center of the crosstube.
3. The tractor is NOT equipped with a cable dozer lift system.
4. The tractor is NOT equipped with a single cylinder dozer lift system.
For an affected tractor, determine which parts are needed. Answer the following four questions to determine which parts are required for a particular tractor.
1. Is the tractor a D8H(22A,35A,36A,46A,52A,and 68A) or a D8K(66V,76V,and 77V)? If D8K, use 168-4428 Lift line Kit and answer question 4. If D8H, answer questions 2 and 3.
2. If D8H, do the lift cylinder hoses mount to the manifold at the center of the crosstube with hose clamps or with split-flange type fittings? If hose clamps, use 170-5928 Lift Line Kit. If split-flange type fittings, use 169-6533 Lift Line Kit.
3. If D8H, does the tube assembly on the right hand lift cylinder mount to the rear face of the quick drop valve or to the inside face of the quick drop valve? If rear face mount, no additional parts are required. If inside face mount, use 177-5006 tube assembly and 9X8873 bolts.
D8H Right Hand Lift Cylinder
4. If D8K, does the customer desire to purchase optional cylinder lines guarding shown in REHS0390-03 or later? IF yes, refer to PS4881 for details on Caterpillar's participation.
Refer to Special Instruction REHS0390 "Procedure to Install the Kit for the Lift Cylinder Lines" and install the new parts in the applicable kit. REHS0390 is packed inside each kit.
NOTE: Make sure that REHS0390-03 or later is used for D8K installations. Make sure that REHS0390-04 or later is used for D8H installations.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
NOTE: This is a 4-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.
NOTE: Do not claim cylinder lines guarding parts. See PS4881 for details on Caterpillar's participation on D8K cylinder lines guards.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
If the 177-5006 Tube Assembly is used on a D8H Track-type Tractor, a 168-4398 Manifold Block, two 1A1460 Bolts, and three 9X8874 Bolts will not be used from the Lift Lines Kit. These unused parts do not need to be returned. The block and botls would be needed in the future if the right hand lift cylinder were exchanged for a latter version cylinder group.
NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.
- (1-Owner Notification)
Copy Of Owner Notification For U.S. And Canadian Owners
