KIT-PLUNGER 2004019 - Caterpillar

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.
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4304" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
April 30, 1999Problem
The interference fit between the bearing and boom at the boom to frame joint, may need to be increased (bore size reduced) on certain 992G Wheel Loaders.
Affected Product
Model & Identification Number
992G (7HR1-131)
The standard and extended lift boom serial numbers are 101-149.
Parts Needed
2 - 1328574 Bearing4 - 1439740 Seal AssemblyAction Required
See the attached Rework Procedure.
Service Claim Allowances
This is a 35-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Tools Needed:
1 - 10 Ton crane or equivalent1 - 9U6702 Puller Bar M64 Thread 2451 mm long2 - 9U6800 Speed Nut M64 Thread1 - 1380992 Flat Plate1 - 1382352 (2 mm offset plate)1 - 5P5201 150 ton press (or larger)1 - inside micrometer to measure bore diameter (must read 9.052 inches) 1 - rosebud torch tip or similar tip1 - hone capable of 9.5" diameter 6" deep bore (slow cutting stones)10 gallons - liquid Nitrogen2.5 gallons - 80 W 90 EP Gear Oil Action Required:
Follow Boom Bearing Removal Procedure to remove the bearings then use Heat Shrink, or Line Boring Procedure to obtain the higher press fit. Both procedures are listed.
BOOM BEARING REMOVAL
1. Remove 'A' joint (see Illustration 1) pins and collars, use machine's hydraulics to push the boom away from the frame. Next use crane to lift boom into workable position. Make sure boom is supported before working on the bore.2. Cut the 1328574 Bearings out with a torch. The bearing will not be used again. Take extra care to not damage the bore with the torch. This can create high spots under the bearing or a leak path. If the bore is damaged, patch weld any gouges and die grind. Cut approximately of the way through the bearing in 4 spots (see Illustration 2). This will relax the bearings enough to allow it to be pulled out with minimal force.
RECOMMENDED PROCEDURE: HEAT SHRINK PROCEDURE
Do not attempt heat shrink procedure if temperature is below 40 degrees F.
3a. After the bore has cooled to ambient temperature, measure bore with a micrometer and record. You will shrink approximately 0.007 inch from the recorded dimension. If the initial bore size is over 9.061 inches, proceed to line boring procedure described below, since you will not be able to shrink the bore enough.3b.