New Hood Rear Mounts Need To Be Installed On Certain D5C Tractors Caterpillar

New Hood Rear Mounts Need To Be Installed On Certain D5C Tractors

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Caterpillar: Confidential Yellow

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 "PI3588" 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 "PI3588" 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 June 4, 1992 Service Letter. A change was made to correct the Termination Date.

Completion Date

December 31, 1992

Termination Date

June 30, 1993

Problem

New rear mounts for the hood need to be installed on certain D5C Tractors. The new mounts and associated parts will better secure the hood, and other portions of the engine enclosure.

Affected Product
Model & Identification Number

D5C (6PJ1-180, 6PJ182-291; 3MK1-213)

Parts Needed

Dealers will need to order parts for this Program.

4 - 5G2878 Washer

4 - 3H2137 Lug

6 - 4L6454 Bolt

8 - 6V2370 Rivet

6 - 7X7729 Washer

4 - 8Y5113 Spring

1 - 8Y7876 Support Assembly (Right Hand)

1 - 8Y7878 Support Assembly (Left Hand)

Action Required

See the attached procedure.

Owner Notification

Not Applicable.

Service Claim Allowances

NOTE: This is a 6-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter 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-Rework Procedure)

Rework Procedure

Part 1. - Fabricate Parts

A. Make two gussets from standard low carbon steel. (See Illustration 1)

B. Make four of "Plate A" from standard low carbon steel. (See Illustration 2)

C. Make four of "Plate B" from standard low carbon steel. (See Illustration 3)

NOTE: Make sure the edges of all the fabricated parts are smooth and free from burrs.

Part 2. - Modification To Engine Side Panel

A. Remove both side engine side panels.

B. Locate and drill 4 - 6.4 mm rivet holes in each panel. Clean all chips and burrs from the holes. (See Illustration 4)

C. Plug the three existing slots in each panel with weld. Use a backup plate for plugging weld. Grind the weld smooth to blend into surrounding material. (See Illustration 4)

D. Secure "Plate A" and the 8Y5113 Spring on each panel with two 6V2370 Rivets. (Two pieces on each panel.)

E. Paint the welded and modified area on each panel.

Part 3. - Modification To Hood

A. Remove the exhaust pipe and precleaner.

B. Remove the four bolts and washers that hold air cleaner housing to hood.

C. Remove the five bolts and washers that hold hood to radiator guard. Remove the three bolts and grommets that hold hood to firewall.

D. Disconnect the electrical wire from horn.

E. Using two people, remove the hood. (the hood weighs approx. 40kg)

F. Cut off the rib plate welded on the rear of the hood using dimensions shown in Illustration 6. Weld both cut ends of the rib plate to the hood using welding instructions in Illustration 6.

G. Position two of the gussets and weld them to the hood using dimensions and welding instructions in Illustration 6.

H. There are three bolt holes in the hood for the bolts that hold the hood to the firewall. Plug weld the center bolt hole using a backup plate. Grind the weld smooth to blend into the surrounding material. (See Illustration 6)

I. Paint the welded areas on the hood

Part 4. - Modification To Firewall

A. Cut the three existing bosses off the firewall.

B. Grind and paint area of firewall where the bosses were removed.

Part 5. - Modification To Main Frame

A. Mark the center lines of the existing four 5h6106/">5H6106 Lugs on the side wall of the main frame. (two lugs on each side) these markings help locate Plate B in Step C. (See Illustration 8)

B. Cut the four 5h6106 lugs off and grind the cut-off area smooth.

C. Position the four Plates B on the main frame to match their centerlines with the markings in Step A and/or using dimensions shown in Illustration 9. Weld Plates B using weld instructions in Illustration 9.

D. Paint the welded areas.

Part 6..Assembly.

A. Install 8Y7876 Support Assembly (Right Hand) and 8Y7878 Support Assembly (Left Hand) on the firewall using two 4L6454 Bolts, two 3H2137 Lugs, two 7X7729 Washers, and two 5G2878 Washers for each support assembly. See Illustration 3.

B. Put the hood in position on the machine.

C. Secure the hood to the support assemblies that were installed on the firewall in "Step A" above. Use two 4L6454 Bolts and two 7X7729 Washers. Use the five bolts and washers removed in Part 3 - Step C to secure the hood to the radiator guard.

D. Secure the air cleaner housing to the hood using the four bolts and washers removed in Part 3 - Step B.

E. Install the exhaust pipe and precleaner.

F. Connect the electrical wire to horn.

G. Install both engine side panels.

GUSSET DIMENSIONS

Illustration 1