PRODUCT IMPROVEMENT PROGRAM FOR CONVERTING TO SPECIAL APPLICATION RIDE CONTROL ON CERTAIN 988G WHEEL LOADERS EQUIPPED WITH LOGGING ARRANGEMENTS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR CONVERTING TO SPECIAL APPLICATION RIDE CONTROL ON CERTAIN 988G WHEEL LOADERS EQUIPPED WITH LOGGING ARRANGEMENTS

Usage:

SEBE7893

January 15, 2002
U-15

Show/hide table

*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR CONVERTING TO SPECIAL APPLICATION RIDE CONTROL ON CERTAIN 988G WHEEL LOADERS EQUIPPED WITH LOGGING ARRANGEMENTS
5004		PI10112

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10112" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI10112" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

A new special application ride control attachment is now available for 988G Wheel Loaders equipped with logging arrangements. Logging machines carry much heavier payloads than standard wheel loaders. The increased capacity and pressure equalization valve of the special application ride control system reduce lift cylinder movement when the ride control system activates. NOTE: The special application ride control attachment is intended for use with 988G Log Loader configurations. Contact Custom Products for compatibility with other configurations.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
988G	2TW138, 166, 321, 323-324, 359, 381, 383, 432, 458, 518

PARTS NEEDED

1 ? 2Q8537 CONT GP - RIDE (KIT) SPECIAL APPLICATION
1 ? 1047108 VALVE GP-CHECK
1 ? 1129783 CONNECTOR
1 ? 3K0360 SEAL
1 ? 4J5477 SEAL

2193001 Hose As (to be fabricated by dealer)
1 ? 8T7096 COUPLING AS
1 ? 8T7097 COUPLING AS
135 CM OF 6V1153 HOSE

NOTE: 2Q8537 KIT GP IS TO BE ORDERED DIRECTLY FROM THE FACTORY THROUGH A MISCELLANEOUS MSO.

NOTE: OTHER PARTS ARE TO BE ORDERED VIA CONVENTIONAL METHODS.

NOTE: The 2Q8537 Kit part list changed after some of the kits were assembled and may need to have three parts replaced as follows:

Show/hide table

2Q8537 KIT GP ? PART CHANGES
Former Part	Replace With
1854026 Valve Gp?Check	1047108 Valve Gp-Check
1897790 Hose As.	2193001 Hose As (Dealer fabricated) See the Parts Needed above for individual parts needed for this assembly See the Illustration section of this Service Letter for an assembly diagram
1488325 Connector As. (1 of 2 in kit)	1545232 Connector As which consists of 1 ? 1129783 Connector 1 ? 3K0360 Seal 1 ? 4J5477 Seal

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	8	0	0	0	0
NOTE: This is a 8.0- hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)
(3-Illustrations)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

Safety - CONVERTING TO SPECIAL APPLICATION RIDE CONTROL

MODELS INVOLVED - CERTAIN 988G WHEEL LOADERS EQUIPPED WITH LOGGING ARRANGEMENTS

Dear Caterpillar Product Owner:

A new special application ride control attachment needs to be installed on the products listed below. Logging machines carry much heavier payloads than standard wheel loaders. The increased capacity of the special application ride control system reduces lift cylinder movement when the ride control system activates. 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 January 15, 2002 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 January 15, 2002 Service Letter

Rework Procedure

NOTE: Engineering drawings are included in the 2Q8537 special application ride control conversion kit. Reference these as required.

Remove the existing ride control accumulator. Refer to Disassembly and Assembly, "Ride Control Accumulator - Remove" for 988G Wheel Loader Machine Systems (Media Number - RENR2173).
Remove the balance of the items required. These are called out on the kit drawing 2Q8537 CONT GP - RIDE (KIT) SPECIAL APPLICATION.
Locate and weld the Block and Plate to the non-engine end frame per kit drawing 1897792 HARDWARE GP - NEEF (HD RC).

Show/hide table

WARNING!

Personal injury can result from from flame cutting or welding on painted areas.

The effect of gasses from burned paint is a hazard to the person doing the cutting or welding.

Do not flame cut or weld on painted areas.

Show/hide table

WARNING! Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc.

Welding can cause fumes, burn skin and produce ultraviolet rays.

Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working.

Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death.

WARNING! Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts.

See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society.

American Welding Society
2501 N.W. 7th Street
Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor
Washington, D.C. 20210

Install the components as indicated per kit drawing 2Q8537 CONT GP - RIDE (KIT) SPECIAL APPLICATION.

Verify accumulator pressures. Refer to Testing and Adjusting, "Ride Control Accumulator - Test and Charge" for 988G Wheel Loader Hydraulic System (Media Number - RENR2171). If the accumulators are not at the proper charge as specified in the manual, bleed off the nitrogen charge to determine if there is oil in the gas chamber. A significant volume of oil in the gas chamber could indicate that the accumulator is defective. Charge the lower accumulator to 4480 +/- 70 Kpa @21 deg. C (70 deg F). Charge the upper accumulator to 7500 +/- 35 Kpa @21 deg. C (70 deg F).

NOTICE

Draining the hydraulic tank causes the brake pump to lose prime.

Failure to reprime the brake pump may result in system damage. All pump lines and pump housing must be filled with oil prior to start-up.

Fill the hydraulic tank to the proper level. Refer to the appropriate Operation and Maintenance Manual for the correct procedure.

Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect" for the machine that is being serviced.