The Engine Air Inlet Lines On Certain Challenger 65C And Challenger 75C Tractors Need To Be Reworked Caterpillar

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 Program must be administered as soon as possible. When reporting the repair, use "PI3645" 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 "PI3645" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

NOTE: This Revised Service Letter replaces the July 29, 1993 Service Letter. Changes have been made to the Parts Needed and the Rework Procedure.

Completion Date

Termination Date

Problem

The engine air inlet lines on certain Challenger 65C and Challenger 75C Tractors may be misaligned and need to be reworked.

Affected Product
Model & Identification Number

CH 65C 2ZJ1-266, 268-311

CH 75C 4KK1-213, 215-301

Parts Needed

Dealers will need to order parts for this Program.

Challenger 65C

2 - 5B9603 Bolt

8 - 9B7237 Bolt

3 - 3E7424 Clamp

2 - 6I0149 Strap

8 - 2K4973 Nut

6 - 5M2894 Washer

1 - 1P6832 Gasket

1 - 1S6595 Gasket

4 - 9S8752 Nut

2 - 1W3011 Spacer

1 - 1078622 Tube - Intake

1 - 1078626 Tube Assembly

1 - 1079096 Bracket Assembly

Challenger 75C

8 - 9B7237 Bolt

3 - 3E7424 Clamp

1 - 6I0141 Hose

2 - 6I0149 Strap

8 - 2K4973 Nut

1 - 1P6832 Gasket

2 - 0341432 Strap

1 - 1078626 Tube Assembly

Action Required

Parts Stock

Remove certain 6I0149 Straps of from parts stock as noted in the attached rework procedure.

Affected Product

See the attached procedure.

Owner Notification

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

Service Claim Allowances

Parts Stock

Submit one claim for all 6I0149 Straps removed from parts stock.

NOTE: US and Canadian Dealers Only - When submitting a parts stock claim use 99Z00001 in the Product Identification Number Field.

Affected Product

NOTE: This is a 2-hour job.

NOTE: U.S. and Canadian Dealers Only - This program does not qualify for a Type 2 SIMS Report.

Parts Disposition

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

NOTE: 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

Rework Procedure

Parts Stock

Remove all 6I0149 Straps from parts stock that were manufactured as shown in Illustration 1. 6I0149 Straps that were manufactured as shown in Illustration 2 are acceptable and should be used for this rework program.

Illustration 1 - Remove 6I0149 Straps of thisconfiguration from parts stock.

Illustration 2 - Use 6I0149 Straps of this configuration for this program

Challenger 65C

1. Remove the air cleaner, mounted on the 6I0694 Intake Tube Assembly, the engine-mounted 6I0693 Intake Tube Assembly, the 6I0699 Support Bracket Assembly and the 9Y2700 Spacers. These parts will not be reused. Keep the 9X4008 and 6I0612 Hoses for reuse.

2. Remove any gasket remaining on the air cleaner.

3. Install 2-1W3011 Spacers on top of the 6I0719 Turbocharger Oil Tube Assembly, install new 1079096 Bracket Assembly on the spacers and secure with 5B9603 Bolts and 5M2894 Washers. Tighten to standard torque.

4. Bend the 6I0149 Straps around the 1078622 Intake Tube.

5. Place the 1078622 Tube Assembly on the 1079096 Bracket Assembly. Insert one end of each strap through its hole in the bracket assembly and loosely install a washer and nut. Install the opposite end of each strap in the same manner. Leave the nuts loose.

6. Assemble the new 1078626 Tube Assembly to the air cleaner, using a new 1P6832 Gasket, 8-9B7237 Bolts and 8-2K4973 Nuts. Tighten to standard torque.

7. Put a new 3E7424 Clamp on each end of 9X4008 Hose.

8. Assemble the 9X4008 Hose onto the tube from the air cleaner. Insert the engine mounted intake tube into the open end of the 9X4008 Hose. Leave both clamps loose.

9. Loosen the 8T4987 Clamp on the turbocharger end of the 6I0692 Hose. Place a clamp on the free end of the 6I0692 Hose (use either the existing 8T4988 Clamp or a new 3E7424 Clamp - select the one that gives the best fit and provides ample tightening adjustment). Leave both clamps loose.

10. Check alignment of all tubes and hoses. Rotate the exhaust elbow down to provide the maximum clearance between the flexible exhaust tubing and the hose on the inlet tubing. When alignments and clearances are sufficient, tighten all hose clamps. Tighten the nuts on the 6I0149 Straps to 8 ± 2 N·m ( 6 ± 1 lb ft).

Challenger 75C

1. Cut the 2 - 341432 Straps securing the harness for the ECM sensor adjacent to the air cleaner. Remove the ECM sensor and the 2N1287 Elbow from the 6I0641 Tube Assembly. Retain these parts for reuse.

2. Remove the 6I0146 Tube Assembly mounted to the air cleaner, and the 6I0141 Hose mounted to the turbocharger. Remove any gasket material remaining on the air cleaner.

3. Bend the new 6I0149 Straps around the 6I0142 Tube. Replace the existing straps with the new straps and leave the new straps loose on the tube.

4. Replace the existing clamps on the 9X4008 Hose with new 3E7424 Clamps. Leave the clamps loose.

5. Assemble the new 1078626 Tube Assembly to the air cleaner with a new 1P6832 Gasket, new 9B7237 Bolts, existing washers, and 2K4973 Locknuts. Tighten to standard torque.

6. Place a new 3E7424 Clamp on the larger end of 6I0141 Hose, and reuse the existing clamp on the smaller end. Assemble the hose onto the turbocharger and the end of the 6I0142 Tube Assembly. Leave the clamps loose.

7. Install the 9X4008 Hose between the engine-mounted 6I0142 Tube Assembly and the air cleaner-mounted 1078626 Tube Assembly. Leave the clamps loose.

8. Check alignment of all tubes and hoses. Adjust to eliminate any stresses or kinks. When alignment is acceptable, tighten all hose clamps. Tighten the strap nuts to 8 ± 2 N·m (6 ± 1 lb ft).

9. Install the 2N1287 Elbow and the ECM sensor in the tube mounted on the air cleaner. Install the 2 - 341432 Straps around the wiring harness.