PRODUCT SUPPORT PROGRAM FOR REPLACING THE LIFT CYLINDERS HOSES AND TUBES ON CERTAIN 966H AND 972H WHEEL LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE LIFT CYLINDERS HOSES AND TUBES ON CERTAIN 966H AND 972H WHEEL LOADERS

Usage:

REBE2815-01

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20Nov2007

(Revised 16Feb2009)

U-601

D-492

O-527

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE LIFT CYLINDERS HOSES AND TUBES ON CERTAIN 966H AND 972H WHEEL LOADERS
5057		PS42560

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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 "PS42560" 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.

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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.

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NOTE:	This Revised Service Letter replaces the 20Nov2007 Service Letter. Changes have been made to the Parts Needed to reflect the latest improvement in the lift lines.

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TERMINATION DATE

30Nov2009

PROBLEM

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Certain 966H and 972H Wheel Loaders may experience early failure of the 244-3336 Lift Hoses. The failure results in blistering/leak of hose at the 90? coupling.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
966H	A6G00117-00985, 995-2145, 2147-2199, 2207-2216
972H	A7G00117-00371, 373-742, 745-747

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*****Group 2*****
966H	A6G02217-02272
972H	A7G00748-00762

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1P3703	SEAL-RECTANGULAR
12	1P3704	SEAL-RECTANGULAR
16	8T4194	BOLT
1	2777117	TUBE AS.
1	2777118	TUBE AS.
1	2777119	TUBE AS.
1	2777120	TUBE AS.
2	2777122	HOSE AS.
1	2777123	BRACKET AS.
1	2777125	BRACKET AS.
2	3448022	HOSE AS
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 2*****
2	1P3703	SEAL-RECTANGULAR
12	1P3704	SEAL-RECTANGULAR
8	8T4194	BOLT
1	2777117	TUBE AS.
1	2777118	TUBE AS.
1	2777122	HOSE AS.
1	2777123	BRACKET AS.
2	3448022	HOSE AS
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

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For Group 1, replace both the right side and left side lift lines (hoses and tubes).

For Group 2, replace only the left side lift lines (hoses and tubes).

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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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*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 4.0-hour job for Group 1

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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*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 4.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

Note: Put identification marks on all lines, hoses, wires, and tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and to keep contaminants from entering the system.

1. Connect the steering frame lock. Refer to the Disassembly and Assembly Manual, "Steering Frame Lock - Separate and Connect".

2. Secure the lift arm, release the tank pressure and remove the front cover referring to the Disassembly and Assembly Manual, "Main Control Valve and Mounting Plate ? Remove".

3. In case of a Command Control Steering machine, please see below. For HMU steering, please go to step 4.

3.1. Disconnect 247-7018, 247-7019, 273-4066 and 273-4067 Hoses from 111-7775 Valve Group Check as shown below:

Image1.1.1

3.2. Remove the bolt and clips which secure the 247-7018 and 247-7019 Hoses.

Image1.2.1

3.3. Remove the 135-4557 Bracket with Valve Group Check.

4. Remove the 245-3219 Hose for dead engine lower valve from main valve.

5. Remove and discard the 244-3336 and 250-4262 Lift Hoses as well as all related seals. Discard sixteen of the 8T-4184 M12 Bolts (45mm long) maintaining lift hoses on lift tubes at their lower part.

6. To remove tube assemblies, first remove bolts maintaining the tube on the main valve, and after remove clamps at the bracket, and remove brackets.
To ease disassembly, we recommend following the sequence 1 to 8 shown below.
The valve shown is a 3 functions valve.
For a 2 functions valve, start the sequence at tube #3.

Image1.3.1

Discard lifts tubes, brackets, and seals. Store half clamps, bolts, and washers for tube reassembly.

7. To install the tubes, refer to the following procedure:
- Install tubes, and hand tight bolts on the main valve in the opposite sequence (8 to 1 for a 3 function valve, or 8 to 3 for a 2 function valve).
- Install 277-7123 and 277-7125 Brackets. Use the two upper holes on the frame thread block to install the brackets.

Bracket locations are shown below.

- Tighten the bolts maintaining the bracket on the frame.
- Adjust position of the tube to have around 10 mm between the tube flange and the clamp.

This will prevent lift hose interference with the front frame.

- Tighten clamps bolts.
- Tighten bolts at the main valve.

8. Install new 344-8022 and 277-7122 Hoses, using the sixteen 8T-4194 M12 Bolts (50mm long) between the new lift tubes and the new hoses. Please see images for hose locations.

9. Install 245-3219 Hose for dead engine lower valve on main valve.

10. Install valve group check and bracket on the frame. Connect lines to valve group check.

11. Start the machine and adjust the hydraulic oil level. Check for leaks and interferences while raising and lowering the lift arm.

12. Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".

Group Number 2

Note: Put identification marks on all lines, hoses, wires, and tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and to keep contaminants from entering the system.

1. Connect the steering frame lock. Refer to the Disassembly and Assembly Manual, "Steering Frame Lock - Separate and Connect".

2. Secure the lift arm, release tank pressure, and remove the front cover referring to Disassembly and Assembly Manual, "Main Control Valve and Mounting Plate ? Remove".

3. In case of a Command Control Steering machine, please see below. For HMU steering, please go to step 4.

3.1. Disconnect 247-7018, 247-7019, 273-4066, and 273-4067 Hoses from 111-7775 Valve Group Check as shown below.

Image2.1.1

3.2. Remove the bolt and clips which secure the 247-7018 and 247-7019 Hoses.

Image2.2.1

3.3. Remove 135-4557 Bracket with Valve Group Check.

4. Remove 245-3219 Hose for dead engine lower valve from main valve.

5. Remove and discard left side 244-3336 and 250-4262 Lift Hoses as well as all related seals. Discard eight of the 8T-4184 M12 Bolts (45mm long) maintaining left side lift hoses on lift tubes at their lower part. Remove right side lift hoses, store hoses and discard seals.

6. To remove tube assemblies, first remove bolts maintaining the tube on the main valve, then remove clamps at the bracket, and remove brackets. To ease disassembly, we recommend following the sequence 1 to 8 shown below. The valve shown is a 3 functions valve. For 2 functions valve, start the sequence at tube #3.

Image2.3.1

Discard 244-3322 and 244-3323 Left Side Lift Tubes, 255-8482 Bracket and seals. Store right side lift lines (tubes and hoses), right side bracket, half clamps, bolts and washers for tube reassembly.

7. To install the tubes, refer to the following procedure:
- Install tubes, and hand tight bolts on the main valve in the opposite sequence (8 to 1 for a 3 function valve, or 8 to 3 for a 2 function valve).
- Install 277-7123 and 277-7125 Brackets. Use the two upper holes on the frame thread block to install the brackets.

Image2.4.1

Bracket locations are shown below.

Image2.5.1

- Tighten bolts maintaining the bracket on the frame.
- Adjust position of the tube to have around 10 mm between the tube flange and the clamp.

Image2.6.1

This will prevent lift hose interference with the front frame.

- Tighten clamps bolts.
- Tighten bolts at the main valve.

8. Install new 344-8022 and 277-7122 Hoses, using the eight 8T-4194 M12 Bolts (50mm long) between the new lift tubes and the new hoses. Please see images for hoses location.

9. Install 245-3219 Hose for dead engine lower valve on main valve.

10. Install valve group check and bracket on the frame. Connect lines to valve group check.

11. Start the machine and adjust the hydraulic oil level. Check for leaks and interferences while raising and lowering the lift arm.

12. Separate the steering frame lock. Refer to the Disassembly and Assembly Manual, "Steering Frame Lock - Separate and Connect".