PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE SYNCHRONIZATION LINES ON CERTAIN 973C TRACK TYPE LOADERS

Usage:

SEBE7858-01

December 11, 2001
(Revised December 2001)
U-339
AU-229
S-179
H-136
O-260

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*Priority* *Parts stock action needed*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE SYNCHRONIZATION LINES ON CERTAIN 973C TRACK TYPE LOADERS
3218 3214		PI30249

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30249" as the Part number and "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 "PI30249" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.

NOTE: This Revised Service Letter replaces the December 11, 2001 Service Letter. Changes have been made to the Action Required and Service Claim Allowances.

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COMPLETION DATE	TERMINATION DATE
June 30, 2002	December 31, 2002

PROBLEM

The synchronization lines need to be updated on certain 973C Track Type Loaders. Fittings in the synchronization lines may fail due to stress created during the assembly process. This may cause the hydraulics system to leak oil and possibly lead to incorrect machine tracking.

AFFECTED PRODUCT

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Model	Identification Number
973C	3RZ1-277, 279-620, 624-628

PARTS NEEDED

4 ? 3J1907 Seal ? O-Ring
4 ? 3J7354 Seal ? O-Ring
8 ? 6V8397 Seal ? O-Ring
2 ? 6V8636 Connector - Seal
2 ? 6V8724 Elbow ? Face Seal
4 ? 6V9872 Connector
2 - 1757683 Tag
2 - 1757684 Tag
2 - 1757685 Tag
2 - 1757686 Tag
1 - 2028545 Body
1 - 2068613 Hose Assembly
1 - 2068614 Hose Assembly
1 - 2068615 Hose Assembly
1 - 2119357 Hose Assembly

ACTION REQUIRED

***** Parts Stock *****

Remove all 1599593 Body parts from parts stock.

***** Affected Product *****

Install new fittings, hoses, and synchronization manifold. See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all 1599593 Body parts that are removed from parts stock.

***** Affected Product *****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
100%	6	0	0	0	0
NOTE: This is a 6-hour job.

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1- Owner Notification)
(2- Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - The Synchronization Lines Need To Be Updated

MODELS INVOLVED - 973C Track Type Loaders

Dear Caterpillar Product Owner:

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated December 11, 2001 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to December 11, 2001 Service Letter

Rework Procedure

This design removes the implement pump priming line (connected from sync block to implement pump inlet) and uses straight fittings/hose ends on the drive pumps.
NOTE: If not already done, relocate the implement oil temperature sensor from the hydraulic tank to the implement pump inlet and plug the port on the hydraulic tank that the sensor was removed from.

NOTE: Mark all hoses for identification purposes before beginning the following procedure.

NOTE: For the purpose of this procedure, the "front" side of the 2028545 Body is actually the side of the block that faces the LH side of the machine when installed. Thus, the "rear" side of the block would be the side that faces the RH side of the machine, when installed. In addition, the towing valves will no longer be used on these machines.

Illustration 1 ? Front View of Lines Group (before rework)

Disconnect the existing synchronization lines from the rear of the existing 1599593 Body.

Illustration 2 ? Rear View of the new 2028545 Body

Illustration 3 ? Top View of the new 2028545 Body

Remove the existing 1599593 Body and remove all fittings from the body. Install the new 2028545 Body. Install two 6V8724 Elbows into the topside of the body in the ports marked "LR" and "RR" (refer to Illustration 3), using one each of a 3J1907 Seal and a 6V8397 Seal. Install two 6V8636 Connectors into the rear side of the body in the ports marked "LF" and "RF" (refer to Illustration 2), using one each of a 3J1907 Seal and a 6V8397 Seal. Reinstall the 6V9200 Elbow that was removed from the 1599593 Body into the upper LH port on the rear side of the body, using a 3J7354 Seal and a 6V8397 Seal. When reinstalling the sync valve on the bottom side of the body, torque the valve to 115 +/- 7 N.m (85 +/- 5 lb. ft). When reinstalling the solenoid over the valve, torque the retaining nut to 3 +/- 0.5 N.m (2 +/- 0.4 lb. ft).

Illustration 4 ? Front View of Lines Group (after rework)

Reconnect the loose end (90 degree) of the 1601506 Hose Assembly to the 6V9200 Elbow located at the upper LH port on the rear side of the new 2028545 Body (refer to Illustration 4).
Remove the "Right Reverse" synchronization line and respective fitting from the RH drive pump and discard these parts. Install a new 6V9872 Connector into the RH drive pump, using a 3J7354 Seal and a 6V8397 Seal. Install a new 2119357 Hose Assembly, connecting one end to the 6V9872 Connector on the pump, and the other end to the 6V8724 Elbow on the top side of the new 2028545 Body located in the "RR" port (refer to Illustration 3). Install the 1757683 Tags onto the new 2119357 Hose Assembly.
Remove the "Right Forward" synchronization line and respective fitting from the RH drive pump and discard these parts. Install a new 6V9872 Connector into the RH drive pump, using a 3J7354 Seal and a 6V8397 Seal. Install a new 2068613 Hose Assembly, connecting one end to the 6V9872 Connector on the pump, and the other end to the 6V8636 Connector on the rear side of the new 2028545 Body located in the "RF" port (refer to Illustration 2). Install the 1757684 Tags onto the 2068613 Hose Assembly.
Remove the "Left Forward" synchronization line and respective fitting from the LH drive pump and discard these parts. Install a new 6V9872 Connector into the LH drive pump, using a 3J7354 Seal and a 6V8397 Seal. Install a new 2068615 Hose Assembly, connecting one end to the 6V9872 Connector on the pump, and the other end to the 6V8636 Connector on the rear side of the new 2028545 Body located in the "LF" port (refer to Illustration 2). Install the 1757686 Tags onto the new 2068615 Hose Assembly.
Remove the "Left Reverse" synchronization line and respective fitting from the LH drive pump and discard these parts. Install a new 6V9872 Connector into the LH drive pump, using a 3J7354 Seal and a 6V8397 Seal. Install a new 2068614 Hose Assembly, connecting one end to the 6V9872 Connector on the pump, and the other end to the 6V8724 Elbow on the top side of the new 2028545 Body located in the "LR" port (refer to Illustration 3). Install the 1757685 Tags onto the 2068614 Hose Assembly.
Reinstall all remaining components that were originally attached to the body in their corresponding locations.