PRODUCT SUPPORT PROGRAM FOR REPLACING THE TILT SENSOR LINKAGE AND GUARDING ON CERTAIN 950H, 962H, 966H, 972H, AND 980H WHEEL LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TILT SENSOR LINKAGE AND GUARDING ON CERTAIN 950H, 962H, 966H, 972H, AND 980H WHEEL LOADERS

Usage:

REBE2898-03

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11Jan2008

(Revised 12Dec2008)

U-24

A-21

D-18

O-20

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TILT SENSOR LINKAGE AND GUARDING ON CERTAIN 950H, 962H, 966H, 972H, AND 980H WHEEL LOADERS
5736		PS51430

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51430" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 11Jan2008 Service Letter. Changes have been made to the Affected Product and to include specific instructions for High Lift Machines.

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TERMINATION DATE

31Jan2010

PROBLEM

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The existing tilt sensor linkage and guarding can become damaged on certain 950H, 962H, 966H, 972H, and 980H Wheel Loaders. If the existing tilt sensor linkage or guarding fails, it can prevent the tilt kickout from functioning.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
950H	J5J00033, 143-615 K5K00117-00352, 354-361, 363-504, 506-517, 519-579, 581-585, 587-588, 590-619, 621-636, 638-666, 668-670, 672-834, 836-863, 865-882, 884-893, 895-906, 908-1025, 1028-1036, 1038-1090, 1092-1111, 1113-1156, 1158-1164, 1166-1203, 1205-1270, 1272-1301, 1303-1573, 1575-1577, 1579-1610, 1613-1616, 1618-1649, 1651-1656, 1658-1810 M1G00150-01181 N1A00102-00136, 138-140, 142-153, 155-169, 171, 173-194, 196-249, 251-277, 279-329, 331-334, 336-343, 345-384, 386-394, 397-428, 430-454, 456-489, 491-530, 532-534, 536-583, 585-662, 664-707, 709-712, 714-719, 721-733, 735-748, 750-754, 756-762, 764-842, 844-865, 867-919, 921-923, 925, 927-936, 938-951, 953-961, 963-992, 994-1018, 1020-1032, 1034-1036, 1038-1040, 1042-1045, 1047-1140, 1142-1170, 1172-1181, 1184-1188, 1190-1191, 1193-1216, 1222, 1224-1250, 1252, 1254-1259, 1261-1293, 1295-1356, 1358-1373, 1375-1403, 1405-1412, 1414-1426, 1428-1436, 1438-1455, 1457-1477, 1480-1506, 1508-1526, 1528-1532, 1534-1559, 1561-1587, 1589-1590, 1592-1595, 1597-1638, 1640-1679, 1681-1690, 1692-1711, 1713-1813, 1815-1857
962H	J6J00146-00244 K6K00117-00188, 190-208, 210-251, 254-308, 310-336 M3G00150-00380 N4A00105, 107-157, 159-206, 208-265, 267-317, 319-504, 508-517, 519-532, 534-558, 560-567, 569-628, 630-640, 642-649, 651-664, 666-707, 709-724

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*****Group 2*****
966H	A6D00117-00118, 120, 122-133, 135-192, 194-320, 322-349, 351-364, 366-455, 457-510, 512, 514-515, 517-519, 521-561, 563, 565, 567-591, 593-605, 607-631, 633, 636-649, 651-686, 688-720, 722-799, 801-827, 829-839, 841-850, 852-889, 891-1001, 1003-1029, 1031-1045, 1047-1054, 1056-1062, 1064-1092, 1094-1117, 1119-1263, 1265-1270, 1272-1316, 1318-1321, 1323-1327, 1329-1334, 1336-1379, 1381-1388, 1390-1402, 1404-1406, 1408-1420, 1422-1423 A6G00117-00152, 155-504, 506-531, 533-551, 553-739, 742-794, 796-813, 815-836, 838-870, 872-940, 944-1044, 1046-1156, 1158-1190, 1192-1211, 1213-1240, 1242-1294, 1296-1307, 1309-1342, 1344-1392, 1395-1471, 1476-1499, 1501-1615, 1617-1618, 1620-1651, 1654-1658, 1660-1690, 1692-1708, 1711-1720, 1722-1755, 1757-1802, 1805-1819, 1822-1832, 1834, 1836-1838, 1840-1877, 1879-1897, 1899-1934, 1936-1954, 1957-1975, 1977-1988, 1990-2003, 2005-2049, 2051-2081, 2084-2096, 2099-2128, 2130-2177, 2179-2183, 2185-2187, 2189-2382, 2384-2411, 2413-2417 A6J00149-00898
972H	A7D00117-00136, 138-178, 180, 182-188, 190-223, 227-233, 235-238, 240-241, 243-278, 280-292, 294-318, 320, 323-348, 350-382, 384, 386-389, 391-479, 481-492, 495-532, 534-549, 551-580 A7G00117-00279, 281-309, 311-325, 327-347, 349-364, 366-382, 384-391, 393-405, 407-413, 415-441, 444-455, 457, 459-487, 489-502, 504-506, 508-550, 553-576, 578, 581-598, 601-627, 629-640, 642-660, 662-721, 723-731, 733-777, 779-805 A7J00150-00272

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*******Group 3*******

980H

A8J00115-00187, 189, 191-194, 196-199, 201-215, 217-275

JMS00225-00244, 246-249, 251-257, 260, 262, 264-315, 317-326, 328-349, 351-366, 368-376, 378-395, 397-424, 426-450, 452-462, 464-465, 467-479, 482-487, 489-527, 529-537, 539-573, 575-601, 603-621, 623-656, 658-663, 665-673, 675-690, 692-708, 710-719, 721-736, 738-744, 746-756, 758-782, 784-801, 803-804, 806-811, 813-830, 832-843, 845-889, 891-919, 921-993, 996, 998-1010, 1012-1077, 1079-1084, 1086-1126, 1129-1133, 1135-1136, 1138-1140, 1142-1143, 1146-1309, 1311-1317, 1319-1329, 1331-1342, 1344-1348, 1350-1392, 1394-1400, 1402-1509, 1511-1531, 1533-1557, 1559-1585, 1587-1595, 1597, 1599-1602, 1604-1627, 1629, 1632-1633, 1635-1681, 1683-1721, 1723-1745, 1747-1750, 1753-1757, 1759-1797, 1799-1804, 1806-1807, 1809-1815, 1818-1824, 1826-1827, 1829-1885, 1887-1941, 1943-2032, 2034-2040, 2042, 2044, 2046-2048, 2050-2057, 2060-2104, 2106-2108, 2110-2117, 2119-2132, 2134-2139, 2141-2164, 2166-2182, 2184-2244, 2246-2356, 2358-2397, 2399-2466, 2468-2486, 2488-2574, 2576-2597, 2599-2642, 2644-2681, 2683-2699, 2701-2712, 2714, 2716-2751, 2753-2759, 2761, 2763-2781, 2783-2792, 2795-2815, 2817-2859, 2861-2954, 2956, 2958-2960, 2962-2963, 2965-2972, 2974-3009, 3011-3056

MHG00100-00102, 105-118, 121, 123-130, 132-152, 154-168, 170-180, 184-212, 214-217, 219-227, 229-244, 246-260, 262-264, 266-345, 352-376, 380-381, 384-401, 403-423, 425-441, 443-444, 446-456, 458-463, 465-469, 471-476, 478-498, 500-529, 532-537, 539-540, 542-564, 566-568, 570-580, 582-591, 593-594, 596-600, 604-637, 640-647, 649-659, 664-666, 668-670, 672, 674-680, 682-690, 692-702, 704-715, 717-727, 729-757, 759, 761-786, 788-789, 791-794, 796-803, 805, 807-808, 810-824, 826-835, 837-851, 853-870, 873, 876-879, 881-886, 888-894, 896-897, 899, 901-905, 908-909, 911-947

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*****Group 4*****
950H	K5K00353, 362, 505, 518, 580, 586, 589, 620, 637, 667, 671, 835, 864, 883, 894, 907, 1026-1027, 1037, 1091, 1112, 1157, 1165, 1204, 1271, 1302, 1574, 1578, 1611-1612, 1617, 1650, 1657 N1A00137, 141, 154, 170, 172, 195, 250, 278, 330, 335, 344, 385, 395-396, 429, 455, 490, 531, 535, 584, 663, 708, 713, 720, 734, 749, 755, 763, 843, 866, 920, 924, 926, 937, 952, 962, 993, 1019, 1033, 1037, 1041, 1046, 1141, 1171, 1182-1183, 1189, 1192, 1217-1221, 1223, 1251, 1253, 1260, 1294, 1357, 1374, 1404, 1413, 1427, 1437, 1456, 1478-1479, 1507, 1527, 1533, 1560, 1588, 1591, 1596, 1639, 1680, 1691, 1712, 1814
962H	K6K00189, 209, 252-253, 309 N4A00106, 158, 207, 266, 318, 505-507, 518, 533, 559, 568, 629, 641, 650, 665, 708

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*****Group 5*****
966H	A6D00119, 121, 134, 193, 321, 350, 365, 456, 511, 513, 516, 520, 562, 564, 566, 592, 606, 632, 634-635, 650, 687, 721, 800, 828, 840, 851, 890, 1002, 1030, 1046, 1055, 1063, 1093, 1118, 1264, 1271, 1317, 1322, 1328, 1335, 1380, 1389, 1403, 1407, 1421 A6G00153-00154, 505, 532, 552, 740-741, 795, 814, 837, 871, 941-943, 1045, 1157, 1191, 1212, 1241, 1295, 1308, 1343, 1393-1394, 1472-1475, 1500, 1616, 1619, 1652-1653, 1659, 1691, 1709-1710, 1721, 1756, 1803-1804, 1820-1821, 1833, 1835, 1839, 1878, 1898, 1935, 1955-1956, 1976, 1989, 2004, 2050, 2082-2083, 2097-2098, 2129, 2178, 2184, 2188, 2383, 2412
972H	A7D00137, 179, 181, 189, 224-226, 234, 239, 242, 279, 293, 319, 321-322, 349, 383, 385, 390, 480, 493-494, 533, 550 A7G00280, 310, 326, 348, 365, 383, 392, 406, 414, 442-443, 456, 458, 488, 503, 507, 551-552, 577, 579-580, 599-600, 628, 641, 661, 722, 732, 778

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*******Group 6*******

980H

A8J00188, 190, 195, 200, 216

JMS00245, 250, 258-259, 261, 263, 316, 327, 350, 367, 377, 396, 425, 451, 463, 466, 480-481, 488, 528, 538, 574, 602, 622, 657, 664, 674, 691, 709, 720, 737, 745, 757, 783, 802, 805, 812, 831, 844, 890, 920, 994-995, 997, 1011, 1078, 1085, 1127-1128, 1134, 1137, 1141, 1144-1145, 1310, 1318, 1330, 1343, 1349, 1393, 1401, 1510, 1532, 1558, 1586, 1596, 1598, 1603, 1628, 1630-1631, 1634, 1682, 1722, 1746, 1751-1752, 1758, 1798, 1805, 1808, 1816-1817, 1825, 1828, 1886, 1942, 2033, 2041, 2043, 2045, 2049, 2058-2059, 2105, 2109, 2118, 2133, 2140, 2165, 2183, 2245, 2357, 2398, 2467, 2487, 2575, 2598, 2643, 2682, 2700, 2713, 2715, 2752, 2760, 2762, 2782, 2793-2794, 2816, 2860, 2955, 2957, 2961, 2964, 2973, 3010

MHG00103-00104, 119-120, 122, 131, 153, 169, 181-183, 213, 218, 228, 245, 261, 265, 346-351, 377-379, 382-383, 402, 424, 442, 445, 457, 464, 470, 477, 499, 530-531, 538, 541, 565, 569, 581, 592, 595, 601-603, 638-639, 648, 660-663, 667, 671, 673, 681, 691, 703, 716, 728, 758, 760, 787, 790, 795, 804, 806, 809, 825, 836, 852, 871-872, 874-875, 880, 887, 895, 898, 900, 906-907, 910

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	4D7794	CLIP
1	4P7582	CLIP-LADDER
5	7X0818	BOLT
4	7X7729	WASHER
1	8T0341	BOLT-SOCKET HEAD
6	8T4121	WASHER-HARD
4	8T4136	BOLT
6	8T4195	BOLT
5	8T4224	WASHER-HARD
2	8T4971	BOLT
1	9M8406	CLIP-LOOP
2	9X8256	WASHER
1	1233202	STRAP-CABLE
1	1686514	SPACER
1	2494134	PLATE
1	2494135	COVER
1	2697250	PLATE
1	2750529	BRACKET AS.
1	3025144	BAIL ARM
1	3257565	SOFTWARE (or newest version)
1	3257570	SOFTWARE (or newest version)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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*****
1	4D7794	CLIP
1	4P7582	CLIP-LADDER
5	7X0818	BOLT
4	7X7729	WASHER
1	8T0341	BOLT-SOCKET HEAD
6	8T4121	WASHER-HARD
4	8T4136	BOLT
6	8T4195	BOLT
5	8T4224	WASHER-HARD
2	8T4971	BOLT
1	9M8406	CLIP-LOOP
2	9X8256	WASHER
1	1233202	STRAP-CABLE
1	1686514	SPACER
1	2494127	BRACKET AS.
1	2494134	PLATE
1	2494135	COVER
1	2655259	BAIL ARM
1	2697250	PLATE
1	3084921	SOFTWARE (or newest version)
1	3085712	SOFTWARE (or newest version)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 3*****
1	4D7794	CLIP
1	4P7582	CLIP-LADDER
5	7X0818	BOLT
4	7X7729	WASHER
1	8T0341	BOLT-SOCKET HEAD
6	8T4121	WASHER-HARD
4	8T4136	BOLT
6	8T4195	BOLT
5	8T4224	WASHER-HARD
2	8T4971	BOLT
1	9M8406	CLIP-LOOP
2	9X8256	WASHER
1	1233202	STRAP-CABLE
1	1686514	SPACER
1	2494127	BRACKET AS.
1	2494130	BAIL ARM
1	2494134	PLATE
1	2494135	COVER
1	2697250	PLATE
1	3282844	SOFTWARE (or newest version)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 4*****
1	4D7794	CLIP
1	4P7582	CLIP-LADDER
5	7X0818	BOLT
4	7X7729	WASHER
1	8T0341	BOLT-SOCKET HEAD
6	8T4121	WASHER-HARD
4	8T4136	BOLT
6	8T4195	BOLT
5	8T4224	WASHER-HARD
2	8T4971	BOLT
1	9M8406	CLIP-LOOP
2	9X8256	WASHER
1	1233202	STRAP-CABLE
1	1686514	SPACER
1	2494134	PLATE
1	2494135	COVER
1	2697250	PLATE
1	2750529	BRACKET AS.
1	2750531	BAIL ARM
1	3257565	SOFTWARE (or newest version)
1	3257570	SOFTWARE (or newest version)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 5*****
1	4D7794	CLIP
1	4P7582	CLIP-LADDER
5	7X0818	BOLT
4	7X7729	WASHER
1	8T0341	BOLT-SOCKET HEAD
6	8T4121	WASHER-HARD
4	8T4136	BOLT
6	8T4195	BOLT
5	8T4224	WASHER-HARD
2	8T4971	BOLT
1	9M8406	CLIP-LOOP
2	9X8256	WASHER
1	1233202	STRAP-CABLE
1	1686514	SPACER
1	2494127	BRACKET AS.
1	2494134	PLATE
1	2494135	COVER
1	2697250	PLATE
1	3032240	BAIL ARM
1	3084921	SOFTWARE (or newest version)
1	3085712	SOFTWARE (or newest version)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 6*****
1	4D7794	CLIP
1	4P7582	CLIP-LADDER
5	7X0818	BOLT
4	7X7729	WASHER
1	8T0341	BOLT-SOCKET HEAD
6	8T4121	WASHER-HARD
4	8T4136	BOLT
6	8T4195	BOLT
5	8T4224	WASHER-HARD
2	8T4971	BOLT
1	9M8406	CLIP-LOOP
2	9X8256	WASHER
1	1233202	STRAP-CABLE
1	1686514	SPACER
1	2494127	BRACKET AS.
1	2494134	PLATE
1	2494135	COVER
1	2697250	PLATE
1	3032242	BAIL ARM
1	3282844	SOFTWARE (or newest version)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Update machine with new tilt sensor linkage and guarding according to 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%

NOTE: This is a 2.0-hour job for Group 1

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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%

NOTE: This is a 2.0-hour job for Group 2

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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 3*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 3

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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 4*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 4

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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 5*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 5

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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 6*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 6

PARTS DISPOSITION

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

Rework Procedure

Remove existing tilt position sensor, linkage and guarding from machine as shown in Image 1.1.1. Retain sensor as it will be reused.

Image1.1.1

Determine whether the 275-0529 Bracket for 950H and 962H (Group 1 and 4) or the 249-4127 Bracket for 966H, 972H, and 980H (Group 2, 3, 5 and 6) has a chain link. If it does not have a chain link, then install the bracket assembly (18) with three 8T-4136 Bolts (7) and three 8T-4121 Hard Washers (6) as shown in the left side of Image 1.2.1. If the bracket assembly does not have a chain link use 4P-7582 Clip (2) as shown in the right side of Image 1.2.1.

Image1.2.1

Install the sensor with five 7X-0818 Bolts (3), five 8T-4224 Hard Washers (9), one 123-3202 Cable Strap (12) and one 4D-7794 Clip (1) as shown in Image 1.3.1.

Image1.3.1

Route the harness through 9M-8406 Clip (13). Secure the clip onto the bracket with 8T-4136 Bolt (7), and 8T-4121 Hard Washer (6) as shown in Image 1.4.1. Connect the harness for the tilt sensor to the harness.

Image1.4.1

Install 249-4134 Plate (15) and 269-7250 Plate (17) around the sensor shaft and install two 8T-4971 Bolts (10) and two 9X-8256 Washers (11) as shown in Image 1.5.1.

Image1.5.1

Install Bail Arm (19) with two 8T-4195 Bolts (8) and two 8T-4121 Hard Washers (6). Install 168-6514 Spacer (14) and install 8T-0341 Bolt (5) onto the end of the Bail Arm as shown in Image 1.6.1. Bail Arm for 950H and 962H Non-High Lift (Group 1) is 302-5144, bail arm for 966H and 972H Non-High Lift (Group 2) is 265-5259 and bail arm for 980H Non-High Lift (Group 3) is 249-4130. Bail Arm for 950H and 962H High Lift (Group 4) is 275-0531, bail arm for the 966H and 972H High Lift (Group 5) is 303-2240 and bail arm for 980H High Lift (Group 6) is 303-2242.

Image1.6.1

Install 249-4135 Cover (16) with four 8T-4195 Bolts (8) and four 7X-7729 Washers (4) as shown in Image 1.7.1.

Image1.7.1

Download the latest implement software from the Service Information System (SIS web) for the model that is being updated. Copy the configuration of the implement ECM with ECM replacement. Flash the new implement software. Program the saved configuration into the implement ECM. Verify that the implement ECM has been configured properly. Cycle power by using the ignition switch. Perform implement calibrations. Refer to Testing and Adjusting, "Electrohydraulic System" for the model that is being updated. Confirm that all fault codes have been cleared.