Usage:
18Jul2007 |
(Revised 01Aug2007) |
Safety Parts stock action needed | PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND IF NECESSARY REPLACING THE TILT CYLINDER HOSE ASSEMBLY ON CERTAIN 988G AND 988H WHEEL LOADERS |
|
5057 5104 | PI10612 |
NOTE: | This Program must be administered as soon as possible.
When reporting the repair, use "PI10612" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim
Description Code and "T" as the SIMS Description Code.
|
NOTE: | This Revised Service Letter replaces the July 18, 2007 Service Letter. Changes have been made to the Parts Needed and Action Required. |
PROBLEM
This service letter supercedes the previous Safety Service Letter, PI10597. The tilt cylinder rod end hose may need to be inspected, or the tilt cylinder rod end hose and tube may need to be replaced with a new hose assembly and manifold on certain 988G and 988H Wheel Loaders. Hose assemblies, which were previously replaced in the field, may fail at the coupling. This failure can cause high-pressure oil to break the windshield, and may result in personal injury or death. There have been no known coupling failures of original factory hose assemblies. On machines that were not previously worked under Safety Service Letter PI10597, replace the tilt cylinder rod end hose and tube with a new hose assembly and manifold. |
AFFECTED PRODUCT
Model | Identification Number |
*******Group 1******* | |
988G | 2TW00074-00090, 92-137, 139-149, 151-162, 164-165, 167-185, 300-303, 305-320, 322, 325-358, 360-380, 382, 384-388, 390-406, 408-409, 411-425, 427-431, 433-456, 459-492, 494-517, 519-539, 541-547, 549-572, 574-584, 586-587, 589-594, 596-626, 629, 631-650, 652-659 |
*******Group 2******* | |
988G | BNH00333-00334, 336-355, 357-394, 397, 399-408, 410-415, 417-424, 426, 428-473, 475-490, 492-506, 508-558, 560-573, 575-583, 585, 587-599, 601-620, 622, 624, 627-632, 634-635, 637-638, 642-650, 653-655, 657-667, 670, 673-674, 676-687, 689-696, 698-737, 740-742, 744, 746-750, 752-754, 756-764, 766-769, 772, 774-775, 778-781, 783-789, 791-798, 800-801, 804-805, 807-813, 816-821, 825, 828-829, 833, 836-837, 839-843, 845, 847-851, 854-857, 859-868, 870-900, 902-903, 905-908, 910, 912-921, 924-927, 929-933, 935-939, 941-944, 946-948, 950-951, 955-956, 958, 960-965, 967-970, 972, 974-979, 981-987, 989-996, 999-1004, 1006, 1008-1020, 1022, 1024-1045, 1047-1058, 1060-1116, 1118, 1120, 1122-1128, 1130-1141, 1144-1145, 1148-1151, 1153-1154, 1156-1159, 1161-1166, 1168-1169, 1171-1181, 1183-1193, 1195-1209, 1211-1214, 1216-1217, 1219-1223, 1225, 1227, 1229-1249, 1251-1257, 1259-1261, 1263, 1265-1267, 1269-1270, 1272-1276, 1278, 1280-1289, 1291-1304, 1306-1307, 1309-1317, 1319, 1321, 1323-1325, 1327-1355, 1357-1378, 1380-1385, 1387, 1389, 1391-1392, 1394, 1396, 1398-1414, 1416, 1418-1424, 1426-1435, 1437-1440, 1442-1452, 1454-1455, 1457-1480, 1482-1503, 1505-1530, 1532, 1534-1536, 1538, 1541-1553, 1555, 1558-1559, 1561-1564, 1567-1579, 1582-1583, 1586-1590, 1592-1595, 1597-1604, 1606-1608, 1610-1617, 1620-1621, 1623-1624, 1626-1631 |
*******Group 3******* | |
988H | BXY00289-00292, 294-295, 298-299, 302-303, 307-308, 310-317, 319, 322, 324-326, 328-331, 333-336, 339-340, 342-348, 350-359, 362-368, 371-374, 376-379, 381-384, 390-392, 397-398, 400-402, 409, 414-417, 420, 426, 431, 433-437, 440-443, 445, 447-448, 450, 454-457, 460-464, 466-468, 470, 474-476, 478, 483, 492, 495-502, 504, 523, 525, 536-537, 539, 543-545, 551-553, 558-559, 561-562, 564-566, 568-569, 572, 574, 577, 579, 582-587, 591-592, 596-597, 600-611, 613-614, 617, 619-625, 628-631, 634-635, 637, 639, 642, 645, 647-651, 654-655, 658, 660, 662-663, 665-666, 668, 670-672, 675-680, 683, 685-686, 688-691, 695, 697-698, 700-702, 704-707, 710, 712, 715-716, 720-724, 728, 730, 733, 737-738, 740, 742-743, 745-748, 751, 755-756, 758-761, 769, 772, 776-777, 779-783, 786-789, 791-793, 796-805, 807, 809-813, 818, 820-829, 831-833, 835-840, 843-844, 846, 849-857, 859, 861-862, 864, 870, 873, 875, 878, 880-881, 883, 889, 891, 894, 896-902, 904, 907-910, 913-915, 917, 920-923, 925, 927, 929-935, 937-938, 940-942, 944-954, 956-957, 962-963, 965, 969, 971, 973-974, 976-979, 981, 985-986, 988, 990, 993-994, 997, 1000-1003, 1006-1008, 1014, 1017, 1019-1021, 1023-1029, 1031-1032, 1034-1035, 1037-1041, 1043-1047, 1050, 1053, 1055, 1059-1061, 1063, 1068-1070, 1072, 1074-1078, 1080-1082, 1084, 1086-1089, 1091-1093, 1095, 1098, 1100-1102, 1104-1105, 1107, 1109, 1111-1112, 1116-1118, 1121-1124, 1131-1132, 1135, 1137, 1144, 1148, 1150, 1152, 1157-1158, 1167, 1172-1173, 1175-1178, 1180-1181, 1186-1191, 1193-1195, 1197-1199, 1206, 1224-1226, 1228, 1232, 1236, 1241, 1243-1246, 1248, 1250, 1253, 1256, 1262-1263, 1267-1268, 1271, 1273, 1275-1278, 1280-1282, 1284-1285, 1288-1292, 1294-1295, 1297-1304, 1306, 1308-1309, 1313, 1315, 1319-1320, 1322, 1327, 1330, 1333, 1335, 1338-1342, 1346-1349, 1352, 1358, 1360-1362, 1370-1372, 1376, 1378, 1382-1383, 1385-1387, 1390-1393, 1395, 1397, 1399, 1402-1404, 1407, 1409, 1412, 1416, 1419, 1421-1422, 1432, 1435-1436, 1439-1441 |
*******Group 4******* | |
988G | 2TW00138, 150, 166, 304, 321, 323-324, 359, 381, 383, 389, 407, 410, 426, 432, 457-458, 493, 518, 548, 573, 585, 588, 595, 627-628, 630, 651 |
*******Group 5******* | |
988G | BNH00335, 356, 395-396, 398, 409, 416, 425, 427, 474, 507, 559, 574, 584, 586, 621, 623, 625-626, 633, 636, 639-641, 651-652, 656, 668-669, 671-672, 675, 688, 697, 738-739, 745, 751, 755, 765, 771, 773, 776, 782, 790, 799, 802-803, 806, 814-815, 822-824, 826-827, 830-832, 834-835, 838, 844, 846, 852-853, 858, 869, 909, 911, 922-923, 934, 940, 949, 952-954, 957, 959, 971, 973, 980, 988, 997-998, 1007, 1021, 1023, 1046, 1059, 1117, 1119, 1121, 1129, 1142-1143, 1146-1147, 1155, 1160, 1167, 1170, 1182, 1194, 1210, 1215, 1218, 1224, 1226, 1228, 1250, 1258, 1262, 1264, 1268, 1271, 1277, 1279, 1290, 1308, 1320, 1322, 1326, 1356, 1379, 1386, 1388, 1393, 1395, 1397, 1415, 1417, 1425, 1436, 1441, 1453, 1456, 1481, 1504, 1531, 1537, 1539-1540, 1554, 1556-1557, 1560, 1565-1566, 1580-1581, 1584-1585, 1591, 1596, 1605, 1609, 1618-1619, 1622, 1625 |
*******Group 6******* | |
988H | BXY00297, 304-306, 320, 323, 327, 337, 341, 360-361, 369, 375, 386, 388-389, 393-394, 396, 399, 403-408, 410, 412-413, 419, 421-425, 428-430, 438-439, 444, 449, 451-453, 458-459, 472-473, 480-482, 485-491, 493-494, 503, 505-510, 515-518, 520, 522, 524, 526-527, 529-535, 540-541, 546-550, 554-556, 560, 570-571, 573, 578, 580-581, 588-590, 594-595, 598-599, 612, 615, 626, 632-633, 636, 640-641, 643-644, 646, 652, 656, 659, 661, 664, 673-674, 681, 684, 692, 694, 696, 699, 708-709, 711, 713-714, 717, 719, 726, 731-732, 734-736, 739, 741, 744, 750, 753-754, 762-763, 766-768, 770-771, 773-775, 778, 784-785, 794-795, 806, 808, 814-817, 830, 834, 845, 847-848, 858, 863, 865-869, 871-872, 874, 876-877, 879, 882, 884-887, 890, 892-893, 895, 903, 906, 911-912, 916, 918, 924, 926, 928, 936, 939, 943, 955, 960, 964, 966-968, 970, 972, 975, 982, 987, 989, 996, 998, 1004-1005, 1009-1013, 1015-1016, 1018, 1022, 1030, 1033, 1036, 1042, 1049, 1051-1052, 1054, 1056-1058, 1062, 1064, 1066-1067, 1071, 1073, 1079, 1083, 1085, 1090, 1094, 1096-1097, 1099, 1103, 1106, 1108, 1110, 1113-1115, 1119-1120, 1125, 1133-1134, 1136, 1138, 1140, 1142-1143, 1145-1147, 1149, 1151, 1153-1156, 1159-1165, 1168-1169, 1171, 1174, 1182-1184, 1201-1205, 1207-1209, 1211-1213, 1215-1216, 1218-1223, 1227, 1237, 1239, 1242, 1251, 1254, 1257-1258, 1261, 1264, 1266, 1269-1270, 1272, 1274, 1279, 1283, 1286-1287, 1293, 1296, 1305, 1307, 1310-1311, 1314, 1316-1318, 1321, 1323, 1325-1326, 1328, 1331-1332, 1334, 1336, 1344-1345, 1350-1351, 1353-1356, 1359, 1365, 1367-1369, 1373-1375, 1377, 1381, 1384, 1389, 1394, 1396, 1398, 1405-1406, 1408, 1410-1411, 1413-1415, 1418, 1420, 1423-1424, 1426-1427, 1429-1431, 1433-1434, 1437-1438, 1442 |
*******Group 7******* | |
988H | BXY00293, 300, 309, 370, 385, 387, 395, 411, 418, 427, 432, 465, 469, 471, 477, 479, 484, 511-514, 519, 521, 538, 542, 557, 563, 567, 638, 653, 657, 667, 669, 682, 687, 693, 703, 718, 725, 727, 729, 749, 752, 757, 764-765, 841-842, 860, 888, 905, 919, 958-959, 961, 980, 983-984, 991-992, 995, 999, 1048, 1065, 1126-1130, 1139, 1141, 1166, 1170, 1179, 1185, 1192, 1196, 1200, 1210, 1214, 1217, 1229-1231, 1233-1235, 1238, 1240, 1247, 1249, 1252, 1255, 1259-1260, 1265, 1312, 1324, 1329, 1337, 1343, 1357, 1363-1364, 1366, 1379-1380, 1388, 1400-1401, 1417, 1425, 1428 |
PARTS NEEDED
Qty |
Part Number | Description |
*******Group 1******* | ||
2 | 1P3705 | SEAL-RECTANGULAR |
1 | 1P3707 | SEAL-RECTANGULAR |
2 | 3E9411 | WASHER-HARD |
4 | 5P8077 | FLANGE-HALF |
1 | 6V1574 | GROMMET |
4 | 7X2475 | BOLT |
4 | 7X2543 | BOLT |
2 | 7X2553 | BOLT |
8 | 7X7729 | WASHER |
4 | 8T4133 | NUT |
8 | 8T4140 | BOLT |
12 | 9X8257 | WASHER |
1 | 1151392 | MANIFOLD |
2 | 2433720 | CLAMP |
1 | 3047225 | HOSE AS. |
2 | 3047226 | BRACKET |
*******Group 2******* | ||
2 | 1P3705 | SEAL-RECTANGULAR |
1 | 1P3707 | SEAL-RECTANGULAR |
2 | 3E9411 | WASHER-HARD |
4 | 5P8077 | FLANGE-HALF |
1 | 6V1574 | GROMMET |
4 | 7X2475 | BOLT |
4 | 7X2543 | BOLT |
2 | 7X2553 | BOLT |
8 | 7X7729 | WASHER |
4 | 8T4133 | NUT |
8 | 8T4140 | BOLT |
12 | 9X8257 | WASHER |
1 | 1151392 | MANIFOLD |
2 | 2433720 | CLAMP |
1 | 3047225 | HOSE AS. |
2 | 3047226 | BRACKET |
*******Group 3******* | ||
2 | 1P3705 | SEAL-RECTANGULAR |
1 | 1P3707 | SEAL-RECTANGULAR |
2 | 3E9411 | WASHER-HARD |
4 | 5P8077 | FLANGE-HALF |
1 | 6V1574 | GROMMET |
4 | 7X2475 | BOLT |
4 | 7X2543 | BOLT |
2 | 7X2553 | BOLT |
8 | 7X7729 | WASHER |
4 | 8T4133 | NUT |
8 | 8T4140 | BOLT |
12 | 9X8257 | WASHER |
1 | 1151392 | MANIFOLD |
2 | 2433720 | CLAMP |
1 | 3047225 | HOSE AS. |
2 | 3047226 | BRACKET |
*******Group 4******* | ||
2 | 1P3705 | SEAL-RECTANGULAR |
1 | 1P3707 | SEAL-RECTANGULAR |
4 | 3E9411 | WASHER-HARD |
4 | 5P8077 | FLANGE-HALF |
1 | 6V1574 | GROMMET |
4 | 7X2475 | BOLT |
4 | 7X2543 | BOLT |
8 | 7X7729 | WASHER |
2 | 8T4132 | NUT |
4 | 8T4133 | NUT |
8 | 8T4140 | BOLT |
2 | 8T4193 | BOLT |
12 | 9X8257 | WASHER |
1 | 1151392 | MANIFOLD |
2 | 2433720 | CLAMP |
1 | 3047224 | HOSE AS. |
2 | 3047226 | BRACKET |
*******Group 5******* | ||
2 | 1P3705 | SEAL-RECTANGULAR |
1 | 1P3707 | SEAL-RECTANGULAR |
4 | 3E9411 | WASHER-HARD |
4 | 5P8077 | FLANGE-HALF |
1 | 6V1574 | GROMMET |
4 | 7X2475 | BOLT |
4 | 7X2543 | BOLT |
8 | 7X7729 | WASHER |
2 | 8T4132 | NUT |
4 | 8T4133 | NUT |
8 | 8T4140 | BOLT |
2 | 8T4193 | BOLT |
12 | 9X8257 | WASHER |
1 | 1151392 | MANIFOLD |
2 | 2433720 | CLAMP |
1 | 3047224 | HOSE AS. |
2 | 3047226 | BRACKET |
*******Group 6******* | ||
2 | 1P3705 | SEAL-RECTANGULAR |
1 | 1P3707 | SEAL-RECTANGULAR |
2 | 3E9411 | WASHER-HARD |
4 | 5P8077 | FLANGE-HALF |
1 | 6V1574 | GROMMET |
4 | 7X2475 | BOLT |
4 | 7X2543 | BOLT |
2 | 7X2553 | BOLT |
8 | 7X7729 | WASHER |
4 | 8T4133 | NUT |
8 | 8T4140 | BOLT |
12 | 9X8257 | WASHER |
1 | 1151392 | MANIFOLD |
2 | 2433720 | CLAMP |
1 | 3047224 | HOSE AS. |
2 | 3047226 | BRACKET |
*******Group 7******* | ||
2 | 1P3705 | SEAL-RECTANGULAR |
1 | 1P3707 | SEAL-RECTANGULAR |
4 | 3E9411 | WASHER-HARD |
4 | 5P8077 | FLANGE-HALF |
1 | 6V1574 | GROMMET |
4 | 7X2475 | BOLT |
4 | 7X2543 | BOLT |
8 | 7X7729 | WASHER |
2 | 8T4132 | NUT |
4 | 8T4133 | NUT |
8 | 8T4140 | BOLT |
2 | 8T4193 | BOLT |
12 | 9X8257 | WASHER |
1 | 1151392 | MANIFOLD |
2 | 2433720 | CLAMP |
1 | 3047224 | HOSE AS. |
2 | 3047226 | BRACKET |
ACTION REQUIRED
Inspect all 304-7224, 304-7225, or 305-3292 Hose Assemblies that were dealer built. Hose assemblies that were built with reusable couplings, need to be scrapped. Hose assemblies that were built using permanent hose couplings, need to be inspected. Refer to the below inspection instructions. |
The new hose assemblies use permanent couplings and have been changed to non-buildable in the HIS (Hydraulic Information System). The hose assemblies must be ordered from Caterpillar through the parts distribution system. Machines which have had cancelled Service Letter PI10597 completed, dealers will need to determine if the hose assemblies were dealer built or ordered from Caterpillar. For these machines three different actions are required. Note: Machines that are equipped with field installed tilt regeneration are not included in this program. If the machine has had the tilt regeneration installed, submit a SIMS report stating that this program is not applicable, and on the claim state that the machine has been installed with tilt regeneration. 1) If cancelled Service Letter PI10597 has been completed with hose assemblies (304-7224, 304-7225, or 305-3292) ordered from Caterpillar, no action is required, except to file an online SIMS report: Part No. "PI-----", Description Code "NA", Comment "PI10597 Cat Hose". This entry is a completion of this program. 2) If cancelled Service Letter PI10597 has been completed with dealer built permanent coupling hose assemblies (304-7224, 304-7225, or 305-3292), the couplings need to be inspected and verified for the proper crimp dimension. Refer to the inspection instructions below. Inspection: Measure the permanent couplings for the correct crimp length and diameter. The full length crimp dimension is 74 mm (2.91 inch) minimum. Use a caliper to measure the coupling diameter at the center of the coupling on four lands. The average for the four measurements should be 62.74 +/- .25 mm (2.47 +/- .01 inch). Document the crimp dimensions on the inspection claim. Hose assemblies with couplings that do not meet this specification should be replaced under this Service Letter, with a new hose assembly ordered from Caterpillar. 3) If cancelled Service Letter PI10597 has been completed with dealer built reusable coupling hose assemblies (304-7224, 304-7225, or 305-3292), they should be replaced under this Service Letter with a new, correct hose ordered from Caterpillar. This may have occurred due to DBS (Dealer Business System) information that was not current. Always refer to the HIS for the latest information. Remove the existing hose assembly, tube assembly, and clip from the left side of the tilt cylinder. Install the new hose, clip, manifold, seals, and hardware. Refer to the Image 1. For Custom machines in groups 4, 5 & 7 (3.6M Boom) a modification is required to the tilt cylinder bracket. Remove the small block from left bottom side of the bracket. Drill two 18mm holes as shown and install two 304-7226 Brackets, two 8T-4193 Bolts, four 3E-9411 Washers and two 8T-4132 Nuts. Refer to Image 2. |
Image1 |
Image2 |
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification. |
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock. |
NOTE: This is a 2.0-hour job for Group 1 | |||||
Submit 1 hour labor for inspection of the crimp dimension of dealer built permanent coupling hose assemblies. Document crimp dimensions on the claim. After the inspection, if it is determined that the hose assembly needs to be replaced, claim the allowances of this service letter. |
NOTE: This is a 2.0-hour job for Group 2 | |||||
Submit 1 hour labor for inspection of the crimp dimension of dealer built permanent coupling hose assemblies. Document crimp dimensions on the claim. After the inspection, if it is determined that the hose assembly needs to be replaced, claim the allowances of this service letter. |
NOTE: This is a 2.0-hour job for Group 3 | |||||
Submit 1 hour labor for inspection of the crimp dimension of dealer built permanent coupling hose assemblies. Document crimp dimensions on the claim. After the inspection, if it is determined that the hose assembly needs to be replaced, claim the allowances of this service letter. |
NOTE: This is a 2.0-hour job for Group 4 | |||||
Submit 1 hour labor for inspection of the crimp dimension of dealer built permanent coupling hose assemblies. Document crimp dimensions on the claim. After the inspection, if it is determined that the hose assembly needs to be replaced, claim the allowances of this service letter. |
NOTE: This is a 2.0-hour job for Group 5 | |||||
Submit 1 hour labor for inspection of the crimp dimension of dealer built permanent coupling hose assemblies. Document crimp dimensions on the claim. After the inspection, if it is determined that the hose assembly needs to be replaced, claim the allowances of this service letter. |
NOTE: This is a 2.0-hour job for Group 6 | |||||
Submit 1 hour labor for inspection of the crimp dimension of dealer built permanent coupling hose assemblies. Document crimp dimensions on the claim. After the inspection, if it is determined that the hose assembly needs to be replaced, claim the allowances of this service letter. |
NOTE: This is a 2.0-hour job for Group 7 | |||||
Submit 1 hour labor for inspection of the crimp dimension of dealer built permanent coupling hose assemblies. Document crimp dimensions on the claim. After the inspection, if it is determined that the hose assembly needs to be replaced, claim the allowances of this service letter. |
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND IF NECESSARY REPLACING THE TILT CYLINDER HOSE ASSEMBLY MODELS INVOLVED - 988G AND 988H WHEEL LOADERS Dear Caterpillar Product Owner: The tilt cylinder rod end hose and tube need to be replaced with a new hose and manifold on the products listed below. Some hoses recently replaced may need to be inspected or replaced. The hose assembly may fail at the coupling causing high pressure oil to break the windshield, and may result in personal injury or death. You will not be charged for the service performed. Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated 18Jul2007 when scheduling this service. We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction. Caterpillar Inc. Identification #(s) Attached to 18Jul2007 Service Letter |