PRODUCT SUPPORT PROGRAM FOR REINFORCING THE STEERING CYLINDER MOUNT AREA ON THE REAR FRAME ON CERTAIN 994 AND 994D WHEEL LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REINFORCING THE STEERING CYLINDER MOUNT AREA ON THE REAR FRAME ON CERTAIN 994 AND 994D WHEEL LOADERS

Usage:

SEBE8187-01

October 18, 2002
(Revised July 2003)
U-277
A-190
AU-205
S-204
H-202
O-225

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REINFORCING THE STEERING CYLINDER MOUNT AREA ON THE REAR FRAME ON CERTAIN 994 AND 994D WHEEL LOADERS
7051		PS41159

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 "PS41159" 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.

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 Revised Service Letter replaces the October 18, 2002 Service Letter. Changes have been made to the Rework Procedure.

Termination Date

October 31, 2004

PROBLEM

The steering cylinders mount on the rear frame needs to be reinforced on 994 and 994D Wheel Loaders. The area where the steering cylinders mount to the rear frame may crack. Reinforcements can be installed to reduce cracking and increase the service life of the frame. This program is an upgraded version of a previous program, PS4521. For those machines that had PS4521 performed, instructions are provided describing the necessary changes to rework those machines to the new design.

AFFECTED PRODUCT

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Model	Identification Number
** Group 1 - already had PS4521 performed **
994 994D	9YF17, 54, 59, 64, 132, 137, 139, 151, 155, 163, 170, 175, 187, 189, 193, 198, 199, 201, 202, 205-208, 217-219 3TZ251-280
** Group 2 - have not had PS4521 performed, and qualify for this program **
994	9YF95, 114, 118, 134, 136, 138, 140, 143, 145, 156, 168, 169, 176, 180, 183, 184, 192, 194-197, 204, 209-216, 220, 221, 223-227

PARTS NEEDED

**** Group 1 ****

No parts required for this rework

**** Group 2 ****

1 - 1606725 Kit

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
** Group 1 **
0-30,000	100%	8	0	0	0	0
NOTE: This is a 8?hour job.
** Group 2 **
0-30,000	100%	58	0	0	0%	0
NOTE: This is a 58?hour job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

**** Group 1 ****

Instructions for reworking those machines that had the original PS4521 completed:

Illustration 1

Illustration 2

Illustration 3

Remove Gusset, cut oval in upper plate, as shown in Illustration 3. Air-Arc material away from lower plate, to dimensions as shown in Illustration 4, grind old weld flush and re-weld 12mm fillet.

Illustration 4

**** Group 2 ****

For necessary instructions, see REHS1644. It will be necessary to remove the front trunnion to do this reinforcement.

Refer to the procedures in the Service Manual.
Park the machine on a level, hard packed surface.
Block up the rear of the machine so that the rear tires are off the ground by a couple of inches.
Remove the drive shaft going to the rear axle.
Remove the 8 bolts that hold the front trunnion to the frame. Do not remove the front trunnion. Loosen only enough to allow the axle assembly to tilt forward so the front trunnion can be removed.
Remove the 12 bolts and front trunnion retainer.
Remove the front trunnion. The approximate weight is 360 kg (792 lb).
When reinstalling the front trunnion, care will be needed to get the trunnion back into position because the new plates make for a tighter fit.