The Lift Cylinder Rod Could Experience A Weld Failure On Certain 928G Wheel Loaders And IT28G Toolcarriers Caterpillar

The Lift Cylinder Rod Could Experience A Weld Failure On Certain 928G Wheel Loaders And IT28G Toolcarriers

Usage:

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Caterpillar: Confidential Yellow

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1405" 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 "PI1405" 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.

Problem

The lift cylinder rod could experience a weld failure on certain 928G Wheel Loaders and IT28G Toolcarriers. This failure is of the weld joint between the yoke and rod. A small number of failures have been reported. It is critical to either have this weld joint inspected by a qualified inspector or to have the lift cylinder rods replaced to address this condition.

Affected Product
Model & Identification Number

928G (6XR785, 6XR787, 6XR794, 6XR795, 6XR798, 6XR800, 6XR801, 6XR804, 6XR805, 6XR809-811, 6XR813, 6XR816-818, 6XR820, 6XR822, 6XR824, 6XR827, 6XR828, 6XR832, 6XR834-838, 6XR841, 6XR844, 6XR846, 6XR851, 6XR853-855, 6XR857, 6XR860, 6XR863, 6XR864, 6XR872, 6XR875, 6XR877, 6XR878, 6XR882-884, 6XR886-888, 6XR890, 6XR891, 6XR894, 6XR898, 6XR905, 6XR906, 6XR911, 6XR916, 6XR917, 6XR919-921, 6XR923, 6XR925-927, 6XR935-940, 6XR943-945, 6XR951-955, 6XR957, 6XR961-964, 6XR966-968, 6XR973, 6XR974, 6XR979-981, 6XR983, 6XR986, 6XR987, 6XR989, 6XR990, 6XR999, 6XR1002, 6XR1005, 6XR1006, 6XR1012-1018, 6XR1020, 6XR1022-1024, 6XR1029, 6XR1032, 6XR1039, 6XR1042, 6XR1047, 6XR1050, 6XR1051, 6XR1053-1055, 6XR1057, 6XR1063-1066, 6XR1068, 6XR1074, 6XR1075, 6XR1077, 6XR1081, 6XR1082, 6XR1089, 6XR1098, 6XR1100, 6XR1101, 6XR1105, 6XR1112, 6XR1114, 6XR1118, 6XR1120, 6XR1122-1129, 6XR1131-1133, 6XR1135-1141, 6XR1143, 6XR1146, 6XR1150-1152, 6XR1155, 6XR1156, 6XR1162, 6XR1164, 6XR1166-1168, 6XR1170, 6XR1177, 6XR1181, 6XR1187-1189, 6XR1192-1195, 6XR1199, 6XR1200, 6XR1205, 6XR1207, 6XR1209-1211, 6XR1213, 6XR1215, 6XR1221, 6XR1228, 6XR1233, 6XR1251, 6XR1258, 6XR1260, 6XR1279 7SR524-805 )

IT28G (8CR851, 8CR854, 8CR858, 8CR859, 8CR861-865, 8CR867, 8CR870, 8CR874, 8CR883, 8CR884, 8CR887, 8CR888, 8CR890, 8CR891, 8CR895, 8CR896, 8CR900, 8CR904, 8CR905, 8CR910, 8CR911, 8CR914-919, 8CR922, 8CR926, 8CR927, 8CR929, 8CR931, 8CR933-937, 8CR942, 8CR948, 8CR951-955, 8CR963, 8CR968, 8CR969, 8CR971, 8CR974, 8CR979-985, 8CR987, 8CR992, 8CR993, 8CR995, 8CR996, 8CR999, 8CR1000, 8CR1002, 8CR1004, 8CR1008, 8CR1009, 8CR1011, 8CR1012, 8CR1014-1017, 8CR1019-1022, 8CR1026, 8CR1028, 8CR1032, 8CR1034, 8CR1035, 8CR1037, 8CR1038, 8CR1043, 8CR1044, 8CR1050-1052, 8CR1054, 8CR1055, 8CR1058, 8CR1063-1065, 8CR1068, 8CR1070-1072, 8CR1078, 8CR1081, 8CR1082, 8CR1088-1091, 8CR1094, 8CR1096, 8CR1098-1101, 8CR1105, 8CR1106, 8CR1108, 8CR1109, 8CR1124, 8CR1127-1130, 8CR1133-1137, 8CR1139-1141, 8CR1146, 8CR1148, 8CR1149, 8CR1151-1154, 8CR1156, 8CR1158, 8CR1161, 8CR1162, 8CR1175, 8CR1177, 8CR1182, 8CR1186, 8CR1187, 8CR1193, 8CR1196-1198, 8CR1201, 8CR1205, 8CR1209, 8CR1211, 8CR1213, 8CR1215, 8CR1219, 8CR1222, 8CR1223, 8CR1225, 8CR1226, 8CR1232-1234, 8CR1237, 8CR1240, 8CR1241, 8CR1243, 8CR1244, 8CR1247, 8CR1248, 8CR1250, 8CR1254, 8CR1256, 8CR1259-1264, 8CR1267, 8CR1277, 8CR1279, 8CR1281-1289, 8CR1291, 8CR1292, 8CR1295-1299, 8CR1301-1307, 8CR1309, 8CR1315-1319, 8CR1333, 8CR1335, 8CR1337, 8CR1341 9AR306-402 )

Parts Needed

2 - 8C3839 Seal Assembly

2 - 8C3840 Seal - Lip Type

2 - 5F3144 Seal - O-Ring

2 - 2J3961 Ring - Back-up

2 - 5J0964 Seal - U-cup

2 - 5J4987 Seal Assembly

2 - 8T0785 Ring - Wear

2 - 8T8390 Ring - Wear

2 - 1191063 Rod Assembly

Action Required

Parts Stock

Inspect all 1191063 Rod Assemblies and remove any defective rod assemblies from Parts Stock. Cylinder groups or rods that have a build date code prior to 1/98 or after 9/98 are not affected, All other material should be reworked.

NOTE: Ensure that all defective rods are destroyed beyond repair or reuse.

Affected Product

See that 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 1191063 Rod Assemblies removed from Parts Stock.

Affected Product

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

This program requires that affected machines be either inspected and/or have the cylinder rods replaced. We have found only a small percentage of machines to have this condition, so an inspection can save down-time and dollars. If an inspection cannot be arranged with a qualified inspector both lift cylinder rods should be replaced.

Inspection:

Inspections of this weld joint can be performed by a qualified inspector, certified in accordance with the requirements of ASNT/SNT-TC-1A, to at least a Level II. An ultrasound inspection of the weld joint can verify the integrity of the weld. If there are questions about inspections, please contact the Joliet Hydraulics Service Engineer at (815) 729-5321.

Rod Replacement:

For dealers with multiple machines, a seed stock of two cylinder heads, two pistons and two piston bolts are authorized to speed the field exchange.

NOTE: To minimize the machine down-time, a piston - cylinder rod - head assembly should be prepared for a machine to be reworked. This way the lift cylinder assembly does not have to be removed from the machine.

Refer to SENR5968 on lift cylinder removal. However, do not remove the lift cylinder assembly from the machine, remove the pin from the lift arm yoke.

1. Unscrew the cylinder head from the cylinder assembly, leaving the cylinder assembly attached to the machine. A 9U7868 Adjustable Wrench Group and a 9U7876 Adapter Plate are necessary to unscrew the head from the cylinder assembly.

2. Remove the piston - cylinder rod - head assembly and replace with the new piston - cylinder rod - head assembly. The old pistons and heads can be rebuilt for the next machine.

3. It is necessary to damage the removed rods beyond repair to assure that these are not able to be reused by mistake.