2015/01/06 Caterpillar

Wheel Loader:

950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)

950M (S/N: EMB1-UP)

962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)

962M (S/N: EJB1-UP)

Description of Change: An improved securing of Tilt Harness for certain Medium Wheel Loaders is now used.

Adaptable To: The improved harness routing provides additional harness length at flex joint and smoother routing without excessive bending/stretching of harness as lift arm moves. The updated design for Tilt Harness has following characteristics:

• Longer Length

• Eliminate sharp bends at clamp

• Uniform stiffness through clamping length

• Rubber Grommets inside the clamps to eliminate sharp pinching of harness at clipping points

Table 1

Required Parts
Item	Qty	Part Number	Description
1	2	178-8505	Plate As
2	4	239-3291	Half Clamp
3	2	388-5576	Weld Boss
4	2	461-8042	Grommet
5	1	463-0097	Sensor Harness As
6	1	463-0098	Sensor Harness As
7	1	4D-7794	Clip
8	2	4K-6177	Clip
9	7	7K-1181	Cable Strap
10	2	7V-5628	Plate
11	4	7X-2534	Bolt
12	4	9X-8256	Washer

The improved Tilt Sensor Harness orientation is adaptable to the following machines:

• 950K (S/N: FER1-3755)

• 950K (S/N: J5M1-1266)

• 950K (S/N: R4A1-2858)

• 950M (S/N: EMB1-353)

• 962K (S/N: FLL1-426)

• 962K (S/N: T6A1-1095)

• 962K (S/N: X4T1-481)

• 962M (S/N: EJB1-186)

The improved Tilt Sensor Harness orientation is effective in production in the following machines:

• 950K (S/N: FER3756-UP)

• 950K (S/N: J5M1267-UP)

• 950K (S/N: R4A2859-UP)

• 950M (S/N: EMB354-UP)

• 962K (S/N: FLL427-UP)

• 962K (S/N: T6A1096-UP)

• 962K (S/N: X4T482-UP)

• 962M (S/N: EJB187-UP)

Rework Procedure

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Illustration 1	g03751816
(A) Existing tilt sensor harness

1. Remove the existing Tilt Sensor Harness (A) and discard. Retain hardware for reuse. Refer to Illustration 1.

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Illustration 2	g03751820
(B) Existing autolube hoses (C) Connection point (D) Existing clips and hardware

2. Illustration 2 shows view of existing Autolube Hoses (B) on machines equipped with Auto Lubrication system.

3. Disconnect the Autolube Hoses (B) at the connection point (C) on lift arm. Refer to Illustration 2.

4. Remove existing clips and hardware (D) on Autolube hoses at two locations. Refer to Illustration 2. Retain hardware for reuse and discard the clips. Do not completely remove the Autolube hoses on the machine except for the two clipping locations shown.

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Illustration 3	g03751837
(E) Existing harness retention plate

5. Remove existing harness retention plate (E) on top right-hand corner of Front Frame. Refer to Illustration 3.

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Illustration 4	g03751841
(1) 178-8505 Plate As (F) 38 mm (1.50 inch) (G) 157 mm (6.18 inch) (H) 69 mm (2.72 inch) (J) 167 mm (6.57 inch)

6. Weld Plate (1) at the location shown on top right-hand corner of Front Frame. All dimensions are shown to the center axis of mounting holes on the weld plate. Refer to Illustration 4.

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Illustration 5	g03751842
(1) 178-8505 Plate As (K) 320 mm (12.60 inch) (L) 320 mm (12.60 inch) (M) 348 mm (13.70 inch) (N) 342 mm (13.46 inch) (P) 135 mm (5.31 inch) (R) 117 mm (4.61 inch)

7. Lower the lift arms so that work tool or bucket is at ground level position. Weld Plate (1) at the location shown on lift arm. Dimensions are shown with respect to existing harness retention plate on lift arm. All dimensions are shown from the center axis of mounting holes on the weld plates. Refer to Illustration 5.

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Illustration 6	g03751845
(3) 388-5576 Weld Boss (S) Existing bosses (T) 108 mm (4.25 inch) (U) 43 mm (1.69 inch) (V) 98 mm (3.86 inch) (W) 145 mm (5.71 inch) (X) 86 mm (3.39 inch) (Y) 114 mm (4.49 inch)

8. Weld two bosses (3) at the locations shown on lift arm. Dimensions are shown with respect to existing bosses on lift arm. All dimensions are shown from the center axis of weld bosses. Refer to Illustration 6.

9. Remove existing two bosses (S) on lift arm. Refer to Illustration 6.

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Illustration 7	g03751847
(2) 239-3291 Half Clamp (4) 461-8042 Grommet (5) 463-0097 Sensor Harness As (6) 463-0098 Sensor Harness As (7) 4D-7794 Clip (10) 7V-5628 Plate (11) 7X-2534 Bolt (12) 9X-8256 Washer

10. Install new Tilt Sensor Harness as shown. Use Sensor Harness As (6) for High Lift Configuration 950 or 962 Wheel Loaders. Use Sensor Harness As (5) for Standard Lift Configuration 950 or 962 Wheel Loaders. Refer to Illustration 7.

11. Retain new Tilt Sensor Harness. Use two Grommets (4), four Half Clamps (2), two Plates (10), four Washers (12), and four Bolts (11). Refer to Illustration 7.

12. Use Clip (7) and existing hardware to retain the harness at location shown. Use two orange tape markings on the harness to locate the clamp across flex joint between front frame and lift arm. Assemble the harness with natural bend arced upwards with a slight bias towards lift arm at the flex joint. Refer to Illustration 7.

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Illustration 8	g03751848
(B) Existing autolube hoses (C) Connection point (D) Existing clips and hardware (8) 4K-6177 Clip

13. Assemble Autolube hoses (B) to two new boss locations on lift arm using two Clips (8) and existing hardware (D). Refer to Illustration 8.

14. Connect the Autolube hoses at the connection point (C) on lift arm. Refer to Illustration 8.

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Illustration 9	g03751849

15. Illustration 9 shows completed view of updated configuration for new Tilt Sensor Harness.