PRODUCT SUPPORT PROGRAM FOR REWORKING THE LEFT-HAND STEERING CONSOLE ON CERTAIN 966K, 972K, AND 980K WHEEL LOADERS
Usage:
REBE7595-00
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| 07Oct2011 |
U-433
O-382
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| Before/After | PRODUCT SUPPORT PROGRAM FOR REWORKING THE LEFT-HAND STEERING CONSOLE ON CERTAIN 966K, 972K, AND 980K WHEEL LOADERS |
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| 5705 3033 4343 3034 | PS43402 |
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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 "PS43402" 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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TERMINATION DATE |
| 31Oct2012 |
PROBLEM
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| The left-hand steering console release cable needs to be inspected on certain 966K, 972K and 980K Wheel Loaders. The cable may have been misrouted at assembly, which can lead to kinking in the release cable. The cable needs to be inspected and rerouted, if necessary. Also, if the cable is kinked, it needs to be replaced as the locking and release mechanism for the left-hand steering console may not function properly. |
AFFECTED PRODUCT
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| Model | Identification Number |
| 966K | PBG00284-00285, 288 TFS00110-00173, 175-207, 210-226, 230, 232-234, 238, 243, 245-246, 249-251, 255, 260, 262 |
| 972K | PEM00267-00268 Z4W00114-00151, 153-182, 186, 188, 196 |
| 980K | W7K00300-00311, 313-317, 319-320, 322-325, 329-333, 348, 353, 359-361, 373 |
PARTS NEEDED
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| No parts needed for this program |
ACTION REQUIRED
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| Requires inspection and possible rework of the left hand steering console release cable. Refer to the attached Rework Procedure for detailed instructions. |
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SERVICE CLAIM ALLOWANCES
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0-24 mo |
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| NOTE: This is a 1.0-hour job | ||||||
| If applicable, reasonable mileage and travel time will be allowed per regional PIP guidelines. |
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| Instructions for Inspecting the Left-Hand Steering Console Release Cable on Certain Medium Wheel Loaders Introduction The left-hand steering console release cable on certain Wheel Loaders may have been misrouted on installation at the factory. Incorrect routing of the cable can cause the cable to kink, and result in improper function of the release and lock mechanism. A new routing is now used in order to improve service life and reliability. Do not perform any procedure in this publication or order any parts until you understand the information that is contained in this publication. Parts Note: Only if cable assembly replacement is required per instruction. Qty Part Number Description 1 369-1863 Cable As 1 369-1864 Clip Note: All hardware removed during this procedure is to be saved and reused. |
| Inspection Procedure 1. Turn off the machine. Lock out the machine. 2. Adjust the armrest to the LOWERED position. 3. Ensure that the joystick pod is fully extended. 4. Check for proper 369-1863 Cable Assembly routing and possible damage to the cable. |
| 5. Remove two 137-6723 Hex Head Screws that secure the 367-5533 Lever Assembly. Refer to Image1.3.1. |
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| Image1.3.1 |
| 6. Remove the 369-1863 Cable Assembly by pulling the lever, removing the cable from the middle slot, and sliding the cable out of the groove. Refer to Image1.4.1. |
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| Image1.4.1 |
| 7. Inspect the cable assembly for damage. Refer to Image1.5.1. Check the last 8 mm (0.315 inch) of the cable assembly for a kink at the die cast barrel end where cable attaches to the 367-5533 Lever Assembly. The cable is kinked in the left-hand picture and the cable is not damaged in the right-hand picture. If the cable is kinked, skip to Step 1 of the Cable Replacement Disassembly Procedure as the cable will need to be replaced. If the cable is not kinked, proceed to Step 8. |
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| Image1.5.1 |
| Incorrect routing of the 369-1963 Cable Assembly. |
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| Image1.6.1 |
| Correct routing of the 369-1963 Cable Assembly. |
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| Image1.7.1 |
| 8. Inspect for correct cable assembly routing. Correct cable assembly routing is between the joystick and the bracket. Refer to Image1.7.1. Incorrect routing of the 369-1863 Cable Assembly is between the cover and the outside of the bracket. Refer to Image1.6.1. |
| 9. If the cable is incorrectly routed, skip to Step 1 of Cable Rerouting Disassembly Procedure. If the cable assembly is correctly routed, proceed to Step 10. |
| 10. Insert and secure the die cast barrel of the cable assembly into the lever assembly. Slide the die cast barrel fully into the round slot of the cable catch on the lever. Refer to Image1.10.1. |
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| Image1.10.1 |
| 11. Pull up on the release lever and snap the snub end coupling on the cable assembly into the center (middle) slot on the lever assembly. Refer to Image1.11.1. If properly assembled, the cable should not contact the lever assembly when the lever is activated. Note: It is critical not to kink the cable during installation. |
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| Image1.11.1 |
| 12. Install the 367-5533 Lever Assembly. Secure the lever assembly with two 137-6723 Screws. Test the lever and the cable assembly for proper function. |
| 13. Ensure the armrest releases and locks properly. |
| Cable Rerouting Disassembly Procedure 1. Loosen the three 9X-2043 Screws on the left side 302-8247 Cover. Refer to Image1.14.1. |
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| Image1.14.1 |
| 2. Lift the release latch and put the armrest in the upright position. |
| 3. Loosen the three 9X-2043 Screws on the left side 302-8247 Cover. Refer to Image1.16.1. |
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| Image1.16.1 |
| 4. Remove the three 138-4854 Screws from the bottom of the cover. Refer to Image1.17.1. |
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| Image1.17.1 |
| 5. Two tabs connect the right and left-hand side covers. In order to remove the 302-8247 Cover without damaging the tabs, push down on the right-hand cover and pull the covers apart. Refer to Image1.18.1. |
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| Image1.18.1 |
| 5a. Incorrect routing of the 369-1863 Cable Assembly. Refer to Image1.19.1. Note: Incorrect routing of the 369-1863 Cable Assembly can result in damage to the cable and improper functioning of the armrest release/locking functionality. |
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| Image1.19.1 |
| 5b. Correct routing of the 369-1863 Cable Assembly. Refer to Image1.20.1. Correct and incorrect routings are shown in the Images1.19.1 and 1.20.1. |
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| Image1.20.1 |
| 6. At the front of the steering console, route the 369-1863 Cable Assembly between the joystick and the bracket. Refer to Images1.20.1 and 1.21.1. Do not route the 369-1863 Cable Assembly between the cover and the outside of the bracket. Refer to Image1.19.1. |
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| Image1.21.1 |
| 7. Reinstall the right-hand 285-7989 Cover. Make sure to pull the 369-1863 Cable Assembly through the hole. Refer to Image1.22.1. The cable assembly should sit freely along the top of the left-hand steering console. Install three 9X-2043 Screws. Tighten the three 9X-2043 Screws on the 302-8247 Cover. Install the three 138-4854 Screws on the bottom of the covers. |
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| Image1.22.1 |
| 8. Insert and secure the die cast barrel of the 369-1863 Cable Assembly into the lever assembly. Slide the die cast barrel fully into the round slot of the cable catch on the lever. Refer to Image1.23.1. |
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| Image1.23.1 |
| 9. Pull up on the release lever and snap the snub end coupling on the cable assembly into the center (middle) slot on the lever assembly. Refer to Image1.24.1. If properly assembled, the cable should not contact the lever assembly when the lever is activated. Note: It is critical not to kink the cable during installation. |
 |
| Image1.24.1 |
| 10. Ensure the armrest releases and locks properly. |
| 11. Install the 367-5533 Lever Assembly and secure with two 137-6723 Hex Head Screws. |
| Cable Replacement Disassembly Procedure 1. Remove the two 253-8798 Knobs and 7X-0578 Hard Washers. Refer to Image1.27.1. |
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| Image1.27.1 |
| 2. Remove the cushion and bracket assembly. Refer to Image1.28.1. |
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| Image1.28.1 |
| 3. Loosen the three 9X-2043 Screws on the 302-8247 Cover. Refer to Image1.29.1. |
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| Image1.29.1 |
| 4. Lift the release latch and put the armrest in the upright position. |
| 5. Remove the three 9X-2043 Screws from the right side 285-7989 Cover. Refer to Image1.31.1. |
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| Image1.31.1 |
| 6. Remove the three 138-4854 Screws from the bottom of the cover. Refer to Image1.32.1. |
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| Image1.32.1 |
| 7. Two tabs connect the right-hand and left-hand side covers. In order to remove the 302-8247 Cover without damaging the tabs, push down on the right hand cover and pull the covers apart. Refer to Image1.33.1. |
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| Image1.33.1 |
| 8. Pop the 369-1863 Cable Assembly out of the slot and remove the cable from the 369-1864 Clip with a flat head screwdriver. Refer to Image1.34.1. Be careful not to break the clip. |
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| Image1.34.1 |
| 9. Remove existing cable assembly from the console. |
| 10. Inspect the 369-1864 Clip for damage. If clip is broken, replace the 369-1864 Clip. |
| 11. Route new 369-1963 Cable Assembly through back of console. Refer to Image1.37.1. |
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| Image1.37.1 |
| 12. Install the new 369-1963 Cable Assembly into the clip. Refer to Image1.38.1. |
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| Image1.38.1 |
| 12a. Incorrect routing of the 369-1963 Cable Assembly. Refer to Image1.39.1. Note: Incorrect routing of the 369-1963 Cable Assembly can result in damage to the cable and improper functioning of the armrest release/locking functionality. |
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| Image1.39.1 |
| 12b. Correct routing of the 369-1863 Cable Assembly. Refer to Image1.40.1. |
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| Image1.40.1 |
| 13. At the front of the steering console, route the 369-1863 Cable Assembly between the joystick and the bracket. Refer to Images1.41.1 and 1.40.1. Do not route the 369-1863 Cable Assembly between the cover and the outside of the bracket. Refer to Image1.39.1. |
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| Image1.41.1 |
| 14. Reinstall the right-hand 285-7989 Cover. Make sure to pull the 369-1863 Cable Assembly through the hole. Refer to Image1.42.1. The cable assembly should sit freely along the top of the left-hand steering console. Install three 9X-2043 Screws. Tighten the three 9X-2043 Screws on the 302-8247 Cover. Install the three 138-4554 Screws on the bottom of the covers. |
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| Image1.42.1 |
| 15. Insert and secure the die cast barrel of the 369-1863 Cable Assembly into lever assembly. Slide the die cast barrel fully into the round slot of the cable catch on the lever. Refer to Image1.43.1. |
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| Image1.43.1 |
| 16. Pull up on the release lever and snap the snub end coupling on the cable assembly into the center (middle) slot on the lever assembly. Refer to Image1.44.1. If properly assembled, the cable should not contact the lever assembly when the lever is activated. Note: It is critical not to kink the cable during installation. |
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| Image1.44.1 |
| 17. Install the 367-5533 Lever Assembly and secure with two 137-6723 Screws. 18. Ensure the armrest releases and locks properly. 19. Reassemble the remaining covers and components using the saved hardware. |
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