PRODUCT SUPPORT PROGRAM FOR INSPECTING AND/OR REPAIRING LIFT CYLINDER DRIFT ON CERTAIN 950H AND 962H WHEEL LOADERS AND IT62H INTEGRATED TOOLCARRIERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND/OR REPAIRING LIFT CYLINDER DRIFT ON CERTAIN 950H AND 962H WHEEL LOADERS AND IT62H INTEGRATED TOOLCARRIERS

Usage:

REBE7877-01

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03May2012

(Revised 24Feb2014)

U-242

A-193

D-205

O-220

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND/OR REPAIRING LIFT CYLINDER DRIFT ON CERTAIN 950H AND 962H WHEEL LOADERS AND IT62H INTEGRATED TOOLCARRIERS
5102 5057 5067		PS43589

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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 "PS43589" 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.

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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.

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NOTE:	This Revised Service Letter replaces the 03May2012 Service Letter. Changes have been made to the Action Required and the Rework Procedure to add a note.

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TERMINATION DATE

31May2014

PROBLEM

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The existing lift cylinder piston seal assemblies may have been damaged due to dieseling on certain 950H and 962H Wheel Loaders and IT62H Integrated Toolcarriers. If the lift cylinder piston seal is damaged, it can leak leading to lift cylinder drift.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
950H	J5J00918-01041, 1043-1197, 1501-1515, 1517-1793 JAD00100, 102, 105-123, 125-142, 145-150, 153-345, 349-351, 357-408 K5K02115-02157, 2159-2227, 2229-2330, 2332-2338, 2340-2341, 2343-2344, 2346-2363, 2365-2383, 2385-2393, 2395-2398, 2400-2404, 2406-2415, 2417-2437, 2439-2447, 2449-2453, 2455-2478, 2480-2493, 2495-2553, 2555-2632, 2634-2655, 2657-2685, 2687-2759, 2761-2810, 2812-2837, 2839-2854, 2856-2861, 2863-2944, 2946-3008, 3010-3025, 3027-3182, 3184-3185, 3187-3189 M1G01488-01561, 1563-1594, 1596-1607, 1614-1647, 1651-1849, 1851-2442, 2800-3018 N1A02292, 2300, 2308-2309, 2311-2312, 2315-2316, 2318, 2320-2332, 2334-2342, 2346-2356, 2358-2373, 2375-2381, 2383-2395, 2397-2403, 2405, 2407-2411, 2422, 2424-2444, 2446-2447, 2449, 2451-2472, 2475, 2479-2499, 2501-2502, 2504-2513, 2525-2527, 2530-2534, 2536-2548, 2550-2563, 2565-2571, 2574-2590, 2594-2595, 2601-2602, 2604-2608, 2610, 2613-2623, 2625, 2627-2637, 2639-2640, 2647-2660, 2664, 2668, 2672, 2674-2678, 2680, 2682, 2684-2695, 2699-2706, 2709-2720, 2722-2732, 2734, 2737-2741, 2746-2748, 2750-2752, 2754-2789, 2791-2804, 2806-2817, 2819-2875, 2877-2882, 2884-2891, 2893-2902, 2904-2914, 2916-2922, 2925-2939, 2943-2948, 2950-2953, 2956-2960, 2962-2966, 2969, 2971, 2973-2976, 2978-2983, 2985-3000, 3002-3034, 3036-3060, 3062-3072, 3074-3079, 3081-3087, 3089-3104, 3106-3112, 3114-3117, 3121, 3123-3125, 3127-3130, 3132, 3134-3137, 3139-3141, 3145-3147, 3150, 3153-3167, 3169, 3171-3173, 3175-3176, 3178-3179, 3182-3183, 3185-3186, 3189-3198, 3200-3209, 3213, 3215, 3217-3219, 3221-3256, 3258-3260, 3262, 3264-3277, 3279-3282, 3285-3286, 3288-3300, 3303-3307, 3309-3312, 3314-3317, 3320-3321, 3323-3324, 3327-3329, 3331-3335, 3337-3339, 3341-3344, 3346, 3348-3351, 3353, 4000-4014, 4016-4020, 4022-4026, 4029, 4033-4037, 4040, 4042-4049, 4051-4054, 4056-4057, 4059-4060, 4062-4066, 4068-4075, 4077-4080, 4082-4089, 4092-4094, 4096, 4098-4099, 4101-4102, 4105-4107, 4109-4113, 4115-4117, 4120-4123, 4126-4128, 4130-4136, 4139-4143, 4146, 4148-4150, 4152-4158, 4160-4162, 4164, 4166, 4168-4170, 4172, 4174-4183, 4185-4186, 4188-4191, 4193-4196, 4198, 4203-4204, 4206-4209, 4211-4217, 4219-4220, 4222-4223, 4225-4226, 4228, 4230-4233, 4235, 4237-4246, 4248-4253, 4255-4263, 4265-4268, 4270, 4274-4280, 4283-4290, 4293-4305, 4308-4310, 4312-4323, 4325-4331, 4333-4342, 4345, 4347, 4349-4364, 4366, 4368-4371, 4373-4389, 4391-4393, 4395-4396
962H	J6J00297-00298, 300-301, 303-305, 307-314, 317-327, 502-504, 506-546 K6K00368-00370, 372-377, 379-387, 389-395, 397-408, 410-412, 414-425, 427-428, 430-439, 441-481, 483-486, 488-516 M3G00459-00835, 1200-1300 MAL00100, 103-119, 121-122 N4A00891-00893, 895-896, 899, 902-905, 907-910, 912-914, 920-955, 957, 960-961, 963-968, 971-977, 979-996, 998-1018, 1021-1022, 1026, 1028-1031, 1035-1040, 1044-1059, 1061-1063, 1067-1068, 1070-1081, 1084-1092, 1094-1100, 1102-1103, 1105-1108, 1110-1114, 1116-1119, 1121-1122, 1124-1141, 1143, 1145-1151, 1155-1156, 1158-1169, 1171-1184, 1186-1193, 1196-1197, 1199-1204, 1206-1209, 1211-1212, 1214-1215, 1217-1218, 1220-1223, 1225-1235, 1237, 1239, 1241, 1245, 1247-1252, 1255, 1258-1259, 1261-1262, 1266-1267, 1269, 1271-1272, 1274-1276, 1278-1285, 2003, 2005, 2007, 2009-2012, 2014-2015, 2019, 2021, 2023, 2027-2030, 2032-2035, 2037, 2041, 2044-2048, 2050-2056, 2058-2059, 2061-2062, 2064-2065, 2067-2070, 2072, 2074-2075, 2077-2078, 2082, 2084-2085, 2087, 2089-2091, 2094-2097, 2100, 2103-2104, 2108-2109, 2111, 2113-2114
962H OEM	L5S00100-00101
IT62H	M5G00414-00478, 600-689

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*****Group 2*****
950H	J5J00883, 1042, 1516 JAD00103-00104, 124, 143-144, 151-152, 346-348, 352-356, 409 K5K02158, 2228, 2331, 2339, 2342, 2345, 2364, 2384, 2394, 2399, 2405, 2416, 2438, 2448, 2454, 2479, 2494, 2554, 2633, 2656, 2686, 2760, 2811, 2838, 2855, 2862, 2945, 3009, 3026, 3183, 3186 M1G01562, 1595, 1608-1613, 1648-1650, 1850 N1A02293-02299, 2301-2307, 2310, 2313-2314, 2317, 2319, 2333, 2343-2345, 2357, 2374, 2382, 2396, 2404, 2406, 2412-2421, 2423, 2445, 2448, 2450, 2473-2474, 2476-2478, 2500, 2503, 2514-2524, 2528-2529, 2535, 2549, 2564, 2572-2573, 2591-2593, 2596-2600, 2603, 2609, 2611-2612, 2624, 2626, 2638, 2641-2646, 2661-2663, 2665-2667, 2669-2671, 2673, 2679, 2681, 2683, 2696-2698, 2707-2708, 2721, 2733, 2735-2736, 2742-2745, 2749, 2753, 2790, 2805, 2818, 2876, 2883, 2892, 2903, 2915, 2923-2924, 2940-2942, 2949, 2954-2955, 2961, 2967-2968, 2970, 2972, 2977, 2984, 3001, 3035, 3061, 3073, 3080, 3088, 3105, 3113, 3118-3120, 3122, 3126, 3131, 3133, 3138, 3142-3144, 3148-3149, 3151-3152, 3168, 3170, 3174, 3177, 3180-3181, 3184, 3187-3188, 3199, 3210-3212, 3214, 3216, 3220, 3257, 3261, 3263, 3278, 3283-3284, 3287, 3301-3302, 3308, 3313, 3318-3319, 3322, 3325-3326, 3330, 3336, 3340, 3345, 3347, 3352, 3354-3355, 4015, 4021, 4027-4028, 4030-4032, 4038-4039, 4041, 4050, 4055, 4058, 4061, 4067, 4076, 4081, 4090-4091, 4095, 4097, 4100, 4103-4104, 4108, 4114, 4118-4119, 4124-4125, 4129, 4137-4138, 4144-4145, 4147, 4151, 4159, 4163, 4165, 4167, 4171, 4173, 4184, 4187, 4192, 4197, 4199-4202, 4205, 4210, 4218, 4221, 4224, 4227, 4229, 4234, 4236, 4247, 4254, 4264, 4269, 4271-4273, 4281-4282, 4291-4292, 4306-4307, 4311, 4324, 4332, 4343-4344, 4346, 4348, 4365, 4367, 4372, 4390, 4394
962H	J6J00291, 294, 299, 302, 306, 315-316, 501, 505 K6K00371, 378, 388, 396, 409, 413, 426, 429, 440, 482, 487 MAL00101-00102 N4A00889-00890, 894, 897-898, 900-901, 906, 911, 915-919, 956, 958-959, 962, 969-970, 978, 997, 1019-1020, 1023-1025, 1027, 1032-1034, 1041-1043, 1060, 1064-1066, 1069, 1082-1083, 1093, 1101, 1104, 1109, 1115, 1120, 1123, 1142, 1144, 1152-1154, 1157, 1170, 1185, 1194-1195, 1198, 1205, 1210, 1213, 1216, 1219, 1224, 1236, 1238, 1240, 1242-1244, 1246, 1253-1254, 1256-1257, 1260, 1263-1265, 1268, 1270, 1273, 1277, 1286, 2000-2002, 2004, 2006, 2008, 2013, 2016-2018, 2020, 2022, 2024-2026, 2031, 2036, 2038-2040, 2042-2043, 2049, 2057, 2060, 2063, 2066, 2071, 2073, 2076, 2079-2081, 2083, 2086, 2088, 2092-2093, 2098-2099, 2101-2102, 2105-2107, 2110, 2112, 2115

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
3	4J0524	SEAL-O-RING
4	7X2550	BOLT-HEX HEAD
2	8T6745	RING-WEAR (After Failure Only)
2	9J4164	RING-WEAR (After Failure Only)
2	1411774	SEAL-O-RING (After Failure Only)
2	2462896	SEAL AS (After Failure Only)
2	2462899	RING-BACKUP (After Failure Only)
2	3465193	SEAL AS-BUFFER (After Failure Only)
2	3465199	SEAL-WIPER (After Failure Only)
2	3465201	SEAL-U-CUP (After Failure Only)
1	3537179	VALVE GP-CHECK-E
1	3566755	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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.
*****Group 2*****
3	4J0524	SEAL-O-RING
4	7X2550	BOLT-HEX HEAD
2	8T6745	RING-WEAR (After Failure Only)
2	9J4164	RING-WEAR (After Failure Only)
2	1411774	SEAL-O-RING (After Failure Only)
2	2462896	SEAL AS (After Failure Only)
2	2462899	RING-BACKUP (After Failure Only)
2	3465193	SEAL AS-BUFFER (After Failure Only)
2	3465199	SEAL-WIPER (After Failure Only)
2	3465201	SEAL-U-CUP (After Failure Only)
1	3537179	VALVE GP-CHECK-E
1	3566758	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 17% 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

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BEFORE FAILURE:

1. Check if the 353-7179 Back Pressure Valve has been installed in the field. If it has not been installed, install the valve and related parts. Refer to REHS4985, Special Instruction, "Field Installation of a Back Pressure Valve in the Return Line on Medium Wheel Loader Machines".

NOTE: Production machines that have been built since the release of this Service Letter may have the backpressure check valve in a different location. The procedure that is covered by this Service Letter requires the valve location as per REHS4985, Special Instruction, "Field Installation of a Back Pressure Valve in the Return Line on Medium Wheel Loader Machines".

2. Perform a cylinder drift test on the lift cylinders.

3. If lift cylinder drift is within specification limits, use the proper procedure to evacuate air from the lift cylinders after installation, before returning the machine to service. Refer to REHS5497, Special Instruction, ?Procedure to Evacuate Air from Cylinders".

4. If lift cylinder drift exceeds specification limits, proceed with the ?AFTER FAILURE? rework procedure below.

AFTER FAILURE:

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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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%
*****Group 1*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 1.0-hour job for Group 1
After failure, an additional 12.0 hours are allowed to rework the cylinder as specified.

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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%
*****Group 2*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 25-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 1.0-hour job for Group 2
After failure, an additional 12.0 hours are allowed to rework the cylinder as specified.

PARTS DISPOSITION

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

Rework Procedure

NOTE: This procedure is to be performed AFTER FAILURE ONLY. Refer to the following Images for repair of the lift cylinders. This information supersedes the piston orientation that was previously shown in the service literature.

1. Check if the 353-7179 Back Pressure Valve has been installed in the field. If it has not been installed, install the valve and related parts. Refer to REHS4985, Special Instruction, "Field Installation of a Back Pressure Valve in the Return Line on Medium Wheel Loader Machines".

NOTE: Production machines that have been built since the release of this Service Letter may have the backpressure check valve in a different location. The procedure that is covered by this Service Letter requires the valve location as per REHS4985, Special Instruction, "Field Installation of a Back Pressure Valve in the Return Line on Medium Wheel Loader Machines".

2. Replace all of the cylinder seals, including piston seals, wear rings, rod seals, and head seals. Refer to RENR8881, Disassembly and Assembly, "Lift Cylinder ? Remove and Install".

3. Install the piston on the rod with the proper orientation. The 9J-4164 Wear Ring should be located toward the rod end of the cylinder. The 246-2896 Piston Seal Assembly should be located toward the head end of the cylinder (toward the piston nut). The piston seal should enter the cylinder barrel first, as the rod assembly is installed into the barrel. Refer to Image1.1.1

Note: The best practice is to use a seal compression tool over the piston seal before installing the rod and piston assembly into the cylinder bore. Refer to drawing FT3190 Seal Compression Tool for tool information.

4. Install the piston seal and wear band onto the piston so that the gaps in the seal and wear band are separated from each other by 45 to 90 degrees. The gaps should NOT be directly in line with the cylinder ports, and should be oriented downward, towards the bottom of the cylinder, when the cylinder is installed in the machine. Refer to Image1.1.2.

5. Use the proper procedure to evacuate air from the lift cylinders after installation, before returning the machine to service. Refer to REHS5497, Special Instruction, "Procedure to Evacuate Air from Cylinders".