Product Support Program For Replacing The Cartridge Style B Pins On Certain 994 And 994D Wheel Loaders Caterpillar

Product Support Program For Replacing The Cartridge Style B Pins On Certain 994 And 994D Wheel Loaders

Usage:

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Caterpillar: Confidential Yellow

NOTE: This Program can 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 "PS40199" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

April 30, 2002

Problem

The cartridge style B Pins may not provide acceptable life. A new greased style B Pin can be installed. The greased pin is connected to the auto lube system.

Affected Product
Model & Identification Number

994 (9YF1-7, 9YF9-121, 9YF124-195, 9YF197-221, 9YF223-226)

994D (3TZ250-256, 3TZ259-263)

Parts Needed

2 - 3J5390 PLUG-PIPE

2 - 3J7354 SEAL-O-RING

4 - 4J5477 SEAL-O-RING

2 - 2T2396 ELBOW

4 - 5T5012 CAP-PROTECT

23 - 8T4121 WASHER-PLATE

8 - 8T4123 WASHER-PLATE

5 - 8T4137 BOLT

2 - 8T4182 BOLT

8 - 8T4184 BOLT

8 - 8t4187/">8T4187 BOLT

16 - 8T4191 BOLT

10 - 8T4223 WASHER-PLATE

8 - 6V8398 SEAL-O RING

2 - 6V8628 ELBOW-SEAL

2 - 6V8789 TEE-SEAL

2 - 7X0492 ELBOW-90 DEG

2 - 7X2550 BOLT

6 - 9R2613 Boss

4 - 9X7699 SEAL-LIP TYPE

2 - 9X8250 Clip

2 - 9X8259 WASHER

2 - 1146060 TUBE AS

24 - 6D3479 CLIP-LOOP

6 - 1332149 SHIM PACK

2 - 1412107 VALVE GP-LUB

2 - 1472001 BOLT-HEX

2 - 1786241 BEARING

4 - 1786242 COLLAR

2 - 1786245 PIN AS.

2 - 1786246 PLATE-SEAL

2 - 1786247 PLATE (30 mm thick)

2 - 1786248 PLATE

2 - 1786249 BLOCK

2 - 1786251 PLATE (20 mm thick)

2 - 1850742 GUARD AS

1 - 1880306 GUARD

1 - 1880309 GUARD

4 - 1883386 BLOCK

1 - 1883387 GUARD

1 - 1883388 GUARD

2 - 1880313 GUARD (High Lift Only)

1 - 1880314 GUARD (High Lift Only)

1 - 1880315 GUARD (High Lift Only)

2 - 1880316 HOSE (High Lift Only)

2 - 1883395 HOSE (High Lift Only)

2 - 1880305 GUARD (STD Only)

1 - 1880307 GUARD (STD Only)

1 - 1880308 GUARD (STD Only)

2 - 1880310 HOSE (STD Only)

2 - 1883394 HOSE (STD Only)

Action Required

See the attached Rework Procedure.

NOTE: With the new pin design, bore and alignment specifications do not change. It is strongly recommended that alignment be checked before attempting to install these new pins. If the bores are out of alignment by a significant amount, the new parts will not fit together.

NOTE: Costs to correct any alignment problems that may be found are not covered by this program.

Service Claim Allowances

Parts Disposition

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

Attach.

1- Rework Procedure)

Rework Procedure

Installation Procedure for Greased B Pins

NOTE: With this new pin design, bore and alignment specifications do NOT change. It is strongly recommended that alignment be checked before attempting to install these new pins. If the bores are out of alignment by a significant amount the new parts will not go together. Force should not be used to deflect a lift arm side plate in order to align the bores. If the bores are forced into alignment the result will be premature failure of the joint. Some force can be used to compensate for sagging of the side plate or uneven position of the structure.

1. Park machine on level hard packed surface. Position the bucket and lift arms so that the clamping bolts can be removed. Block the bucket and lift arms to prevent movement.

NOTE: It is not necessary to disconnect the tilt links.

2. Remove the existing B pins and collets.

3. Ensure that the new collars (1786242) are a slip fit in the bucket bores.

4. Install the collars in the bores. Install the pins (1786245) with the flags on the outboard side. Center the pins laterally in the hinge plates.

5. Install the 1786249 Blocks, 1786248 Plates, 8t4187 Bolts, 8T4123 Washers, 7X2550 Bolts and 8T4223 Washers. Tighten the bolts hand tight. See Illustration 1 and 2.

6. With the opening in the block centered around the flag, determine what thickness of 1786247/1786251 plate is needed (included plates are 20 and 30 mm thick, some buckets may require a thicker or thinner plate depending on the bucket ).

7. Tack weld the plate and block in position as shown in Illustration 1. Remove the pins and collars. Weld the plates and blocks in position.

8. Locate the 2 1883386 Blocks on each end of the lift arms. See Illustrations 4 and 5. To make positioning easier, bolt the blocks to the guards that will cover them and then tack weld in position. Remove the guards. Use a spacer that is slightly narrower than the gap between the two blocks and secure in place using 2 C clamps. This will help maintain spacing while welding the blocks.

9. Locate and weld 2 9R2613 bosses to the ends of the lift arms and install 4 more bosses on the cross tube. See Illustrations 3 and 5.

10. Remove the plugs in the lift arm that are positioned above the B pin bores. Thoroughly clean the holes of any debris or contaminates.

11. Install the 9X7699 Seals in the 1786241 Bearings. Coat the bore of the bearings with grease.

12. Install the 1786241 Bearings in the lift arm bores. Use a small diameter rod to ensure that the grease passage in the bearing is aligned with the hole in the lift arm. At the same time center the bearing laterally in the lift arm bore. Minimum of 3 mm projection from either side. Tighten the clamping bolts to standard torque. See Illustration 2.

13. Install the collars and pins. Install the 1786246 Plates, 9X8259 Washers and 1472001 Bolts. Tighten the bolts to 2000 lb ft.

14. Install the 1786248 Plates, 8T4123 Washers and 8t4187/">8T4187 Bolts. Center the flags of the pins side-to-side in the opening in the 1786249 Blocks by either moving the bucket or moving the lift arms (steer the machine right or left). Install shims on both sides of the flags of the pins. Shim the inboard side of the flag on the pin tight. Shim the outboard side so that there is 0.005-0.010" clearance on each side after installing the shims. Install the 8T4223 Washers and 7X2550 Bolts.

NOTE: High lift part numbers are in (xxxxx).

15. Position the 188-0305, 188-0306, 188-0307, 188-0308, 188-0309 (188-0306, 188-309, 188-0313, 188-0314, 188-0315) Guards on the inboard side of the lift arm side plates as shown in the Illustration. Mark the location of the holes in the guards that will be used for welding. Remove the guards and remove the paint from the lift arms in the area of the marked holes. Put the guards in position and weld them as shown in Illustration 4.

NOTE: Before installing the 185-0472 Guard Assemblies ensure that the existing grease supply line will reach the guard assembly.

16. Install 185-0472 Guard Assemblies as shown in the Illustration 4 and 5.

17. Install the 141-2107 Valve Groups (injectors) in the guard assemblies.

18. Connect the grease supply lines as shown in the Illustrations 4 and 5.

NOTE: Prefill the hose assemblies with grease.

19. Install the fittings and 188-0310 Hose Assemblies (188-0316 Hose Assemblies)

20. Reposition the grease lines going to the tilt levers to the new bosses added in step 9.

21. Install the clips, bolts and washers.

22. Remove the plug at the injectors and manually grease the B pins until grease is visibly passing the seal at the new B pins.

23. Adjust the injectors so that they are open as much as possible.

24. With adequate clearances, operate the linkage slowly through its entire motion 2-3 times.

25. Check for interference between the 188-3388 and 188-3387 Guards and the tear drops on the bucket. If there is interference, remove enough material from the corner of the guard to prevent the interference.

Illustration 1.