PRODUCT SUPPORT PROGRAM FOR REPLACING CAB DOOR LOCK MECHANISM AND FASTENERS ON CERTAIN 365C, 374D, 385C, AND 390D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING CAB DOOR LOCK MECHANISM AND FASTENERS ON CERTAIN 365C, 374D, 385C, AND 390D EXCAVATORS

Usage:

TEBE0385-00

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10Oct2013

U-497

A-342

D-411

O-415

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING CAB DOOR LOCK MECHANISM AND FASTENERS ON CERTAIN 365C, 374D, 385C, AND 390D EXCAVATORS
7308		PS52537

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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 "PS52537" 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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TERMINATION DATE

31Oct2015

PROBLEM

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The existing cab door lock mechanism can fail on certain 365C, 374D, 385C, and 390D Excavators. This failure is due to lock mechanism inner thread stripping.

AFFECTED PRODUCT

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Model	Identification Number
365C L	ELC00156-00602, 78001-78002
374D L	PAP00121-00289 PAS00131-00204, 400-870 PAX00111-00164, 300-436
385C	KKK00123-00226 MNZ00124-00172
385C L	EDA00189-00557 KGB00275-00498 SBE00168-00529 T2E00291-00341
390D	BYP00121-00130 KCZ00151-00179
390D L	WAG00131-00241 WAP00171-00532 WBT00141-00277

PARTS NEEDED

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Qty	Part Number	Description
1	1566600	LOCK AS
3	1858180	SCREW AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Replace the failed cab door lock with a new 156-6600 Lock Assembly and three 185-8180 Screw Assemblies with proper specified tightening specifications.

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%
0-2000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
6001-10000 hrs, 25-36 mo	7.0%	5.0%	0.0%	0.0%	70.0%	95.0%

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NOTE: This is a 1.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Prior to starting the Rework Procedure, ensure that appropriate walkways and handrails are used in order to work in a safe environment. Refer to Image1.1.1.

Image1.1.1

1. Remove the door lock mechanism lower cover by removing the two screws. Refer to Image1.2.1.

Image1.2.1

2. After pushing out the cover, remove one of the two screws holding the door handle, to allow access to the three door lock mechanism middle cover screws. Refer to Image1.3.1.

Image1.3.1

3. Remove the lock mechanism middle cover by removing the three screws. Refer to Image1.4.1.

Image1.4.1

4. In order to ease lock mechanism removal, remove the the three screws that hold the external grab handle. Refer to Image1.5.1.

Image1.5.1

5. Release both lock mechanism lower rods by unclipping their plastic joints. Refer to Image1.6.1.

Image1.6.1

6. Release the lock mechanism upper rod by unclipping its plastic joint. Refer to Image1.7.1.

Image1.7.1

7. Remove the failed lock mechanism by removing three screws and sliding it out through the door opening. Refer to Image1.8.1. and Image1.8.2.

Image1.8.1

Image1.8.2

8. Slide in the new 156-6600 Lock Assembly and tighten the new 185-8180 Screw Assemblies to a specified torque of 6 +/- 1 N.m. Exceeding this tightening specification could lead to lock assembly inner thread stripping. Refer to Image1.9.1 and Image1.9.2

Image1.9.1

Image1.9.2

9. Connect the 156-6600 Lock Assembly upper rod by clipping its plastic joint. Refer to Image1.10.1.

Image1.10.1

10. Connect both of the 156-6600 Lock Assembly lower rods by clipping their plastic joints. Refer to Image1.11.1.

Image1.11.1

11. Fasten the external grab handle by tightening the three screws to a specified torque of 12 +/- 3 N.m. Refer to Image1.12.1.

Image1.12.1

12. Install the lock assembly middle cover by tightening the three screws to a specified torque of 12 +/- 3 N.m. Refer to Image1.13.1.

Image1.13.1

13. Fasten the door handle by the screw to a specified torque of 12 +/- 3 N.m. Install the related plastic cover. Refer to Image1.14.1.

Image1.14.1

14. Install door lock assembly lower cover by tightening the two screws to a specified torque of 12 +/- 3 N.m. Refer to Image1.15.1.

Image1.15.1

15. Check for proper lock assembly functions. Close and open the door from both inside and outside the cab while using related grab handle. Adjust the door striker, if necessary. Ensure that the key provides the intended locking function.