PRODUCT SUPPORT PROGRAM FOR REPAIRING THE FLOW SHARING VALVE AND STEERING VALVE ON CERTAIN 988K WHEEL LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE FLOW SHARING VALVE AND STEERING VALVE ON CERTAIN 988K WHEEL LOADERS

Usage:

TEBE3894-00

Show/hide table

04Jan2016

U-7

A-6

D-5

O-5

Show/hide table

Before/After	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE FLOW SHARING VALVE AND STEERING VALVE ON CERTAIN 988K WHEEL LOADERS
5051		PS44954

Show/hide table

NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS44954" 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.

Show/hide table

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.

Show/hide table

TERMINATION DATE

31Jan2018

PROBLEM

Show/hide table

The 9J-8126 Orifice Plug in the 370-6919 Control Valve Group and the 4T-4207 Orifice Plug in the 361-2413 Control Valve Group were not installed with the correct torque on certain 988K Wheel Loaders. During operation the orifice plugs may fall out resulting in internal damage to the valve. If internal damage to the 370-6919 Control Valve Group or the 367-2413 Control Valve Group occurs, the machine may experience the following issues:

SOS samples may show elevated Iron (FE) PPM
SOS samples may show fluid cleanliness above ISO 18/15
Excess flow solenoid calibration may fail
Implement cycle times may be slow at low idle
Steering performance may be reduced

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
988K	LWX00125, 501-539, 600-637, 639-645, 647-649, 651-652 TWX00150-00156, 201-502, 600-771, 773-778, 780-782

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	3J7354	SEAL-O-RING-STOR (After Failure Only)
1	4T4207	PLUG-NPTF (After Failure Only)
2	4T5074	RING-BACKUP (After Failure Only)
1	5M2057	SEAL-O-RING (After Failure Only)
2	6V5556	SEAL-O RING (After Failure Only)
2	7M8485	SEAL-O-RING-STOR (After Failure Only)
1	9J8126	PLUG-NPTF (After Failure Only)
1	2147567	SEAL-O-RING-STOR (After Failure Only)
1	3612422	SLEEVE (After Failure Only)
1	3612426	SPRING (After Failure Only)
1	3706936	SPRING (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

Show/hide table

The 9J-8126 Orifice Plug and the 4T-4207 Orifice Plug must be tightened to a specified torque of 12 +/- 2 N.m (9 +/- 1.5 lb ft). Follow the steps below to complete the tightening. Refer to Image1 for the control valve location.

1. Remove 367-6002 Plug As (G) from 370-6919 Control Valve Group and remove 371-7186 Plug As (J) from the 361-2415 Control Valve Group. Refer to Image2 and 3.

Note: Step 2 requires a 4mm (5/32 inch) male hex driver with a minimum length of 70mm (2.75 inch) to engage orifice plugs.

2. Tighten the 9J-8126 Orifice Plug in 370-6919 Control Valve Group and 4T-4207 Orifice Plug in 361-2415 Control Valve Group to a specified torque of 12 +/- 2 N.m (9 +/- 1.5 lb ft). Install 371-7186 Plug Assembly and 367-6002 Plug Assembly. Tighten both plugs to a specified torque of 25 +/- 4 N.m (18 +/- 3 lb ft).

IMPORTANT: If the orifice plug is not in the proper location, damage to the control valve may result. Repair of damaged control valve parts is required. Refer to the attached control valve Rework Procedure.

Show/hide table

Image1

Image2

Image3

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-5000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
5001-8000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

Show/hide table

NOTE: This is a 1.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Note: An additional 2.0 hours of labor may be claimed for an After Failure repair.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

Control Valve Repair Procedure:

The following is the repair procedure for 370-6919 Control Valve Group. Refer to Image1.1.1.

1. Remove 4T-1649 Housing (E), 361-2422 Sleeve (3), 4B-4278 Washer (F), and 370-6936 Spring (5).

2. Remove compensator spool (D) from valve bore with a magnet. If magnet will not remove compensator from bore, remove 100-8011 Plug (A), 2S-2596 Spring (B), and 100-8010 Check Valve (C). Drive the compensator spool out of bore with a brass rod and hammer.

Image1.1.1

3. Use a disc buffer to remove damage to the compensator spool. Refer to Image1.2.1 and 1.2.2.

4. Use a die grinder to remove damage to edge of land in bore. The bore is approximately 28mm (1.1 inch) in diameter.

5. Use approved solvent and a magnet to clean debris from valve bore and surrounding cavities.

6. Install compensator spool into bore. Check repair by spinning and sliding the compensator spool in the bore using a magnet. Movement should be free and smooth. Refer to Image1.1.1 above.

7. Reinstall 100-8011 Plug (A), 2S-2596 Spring (B), and 100-8010 Check Valve (C), as needed.

8. Install new 9J-8126 Orifice Plug (2). Tighten to a specified torque of 12 +/- 2 N.m (9 +/- 1.5 lb ft).

9. Install 367-6002 Plug Assembly (G). Tighten to a specified torque of 25 +/- 4 N.m (18 +/- 3 lb ft).

10. Replace 361-2422 Sleeve (3), 4T-5074 Backup Ring, 6V-5556 O-Ring Seal, and 370-6936 Spring (5) with new. Reuse 4B-4278 Washers (F).

11. Install 4T-1649 Housing (E).

Image1.2.1

Image1.2.2

The following is the repair procedure for 361-2415 Control Valve Group. Refer to Image1.3.1.

1. Remove 361-2429 Pressure Control Valve Group (H), 4B-4278 Washer (F), and 361-2426 Spring (11).

2. Remove compensator spool (D) from valve bore with a magnet. If magnet will not remove compensator from bore, remove 100-8011 Plug (A), 2S-2596 Spring (B), and 100-8010 Check Valve (C). Drive the compensator spool out of bore with a brass rod and hammer.

3. Use a disc buffer to remove damage to compensator spool (D) and 361-2429 Pressure Control Valve Group (H). Refer to Image1.2.1 and 1.2.2.

Image1.3.1

4. Use a die grinder to remove damage to edge of land in bore. The bore is approximately 28mm (1.1 inch) in diameter.

5. Use approved solvent and a magnet to clean debris from valve bore and surrounding cavities.

6. Install compensator spool into bore. Check repair by spinning and sliding the compensator spool in the bore using a magnet. Movement should be free and smooth. Refer to Image1.3.1 above.

7. Reinstall 100-8011 Plug (A), 2S-2596 Spring (B), and 100-8010 Check Valve (C), as needed.

8. Install new 4T-4207 Orifice Plug (10). Tighten to a specified torque of 12 +/- 2 N.m (9 +/- 1.5 lb ft).

9. Install 371-7186 Plug As (J). Tighten to a specified torque of 25 +/- 4 N.m (18 +/- 3 lb ft).

10. Replace 4T-5074 Backup Ring, 6V-5556 O-Ring Seal, and 361-2426 Spring (11) with new. Reuse 4B-4278 Washers (F).

11. Install 361-2429 Pressure Control Valve Group (H).

Note: If SOS Analysis indicates ISO fluid cleanliness above 18/15 or elevated wear metal PPM, filter the hydraulic system. Follow SEBF8494, "Procedure for Filtering Large Wheel Loader and Landfill Compactor Hydraulic Oil".