PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL ELECTRIC PARTS AND A HARNESS ON CERTAIN 538 GF FORESTRY EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL ELECTRIC PARTS AND A HARNESS ON CERTAIN 538 GF FORESTRY EXCAVATORS

Usage:

TEBE5195-00

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30Sep2016

U-519

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL ELECTRIC PARTS AND A HARNESS ON CERTAIN 538 GF FORESTRY EXCAVATORS
5734 1408 5057 5059		PI32684

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32684" 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 "PI32684" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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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COMPLETION DATE	TERMINATION DATE
31Mar2017	30Sep2017

PROBLEM

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Electric parts and a harness were not installed on certain 538 GF Forestry Excavators. Without this modification certain forest hydraulic tools cannot be installed.

AFFECTED PRODUCT

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Model	Identification Number
538 GF	HBS00139, 141, 145

PARTS NEEDED

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Qty	Part Number	Description
1	BULK_OIL	HYDRAULIC OIL 1 LITER (IF REQUIRED)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Install additional electric parts and a new harness. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 6.0-hour job
Note: All parts needed have been shipped directly to the dealership prior to the release of this Service Letter program.

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PARTS DISPOSITION

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

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL ELECTRIC PARTS AND A HARNESS

MODELS INVOLVED - CERTAIN 538 GF FORESTRY EXCAVATORS

Dear Cat Product Owner:

Additional electrical parts and a harness need to be installed on the products listed below. Without this modification certain forest hydraulic tools cannot be installed. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 30Sep2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 30Sep2016 Service Letter

Rework Procedure

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NOTE: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".?

1. Park the machine on a hard level surface, and ground the bucket/tool. Refer to the Operation and Maintenance Manual.

2. Stop the engine and lock the hydraulic lockout control.Ensure that all residual pressure is removed. Refer to M0071454, Disassembly and Assembly, "System Pressure - Release", for additional information.

3. Raise up the cab.

NOTE: All rework parts have been shipped directly shipped to the dealership prior to the release of this Service Letter program. Refer to Image1.2.1.

Image1.2.1

4. Remove green tag hose (A) and orange tag hose (B). Refer to Image1.3.1.

5. Remove adapter assembly (C). Refer to Image1.3.1.

Image1.3.1

6. Install two 321-8612 Plug Assemblies (D) to the removed green tag and orange tag hoses. Refer to Image1.4.1. Tighten the two plug assemblies to a specified torque of 45 +/- 5 N.m.

Refer to Step 9.

Image1.4.1

7. Install two 148-8305 Adapter Assemblies (E). Tighten to a specified torque of 55 +/- 8 N.m. Refer to Image1.5.1.

8. Install two 319-4407 Pressure Switch Assemblies (F). Tighten to a specified torque of 29 +/- 3 N.m.

Refer to Step 19 for the harness connection.

Image1.5.1

9. Install 7K-1181 Cable Straps (G) to the green tag hose, orange tag hose, and neighbor hoses. Refer to Image1.6.1.

Image1.6.1

10. Remove the four bolts and clip. Retain the bolts and clip for later reuse. Refer to Image1.7.1. Refer to Step 17.

11. Remove the pressure switch. Retain the pressure switch for later reuse. Refer to Image1.7.2. Refer to Step 16.

Image1.7.1

Image1.7.2

12. Install 148-8326 Adapter Assembly (H) on the valve block. Tighten to a specified torque of 30 +/- 5 N.m. Refer to Image1.8.1.

13. Install 5I-4376 Adapter Tee (J). Tighten to a specified torque of 45 +/- 5 N.m. Refer to Image1.8.2.

14. Install 447-8265 Pressure Sensor (K). Tighten to a specified torque of 32.5 +/- 2.5 N.m.

15. Install 148-8305 Adapter Assembly (M). Tighten to a specified torque of 55 +/- 8 N.m.

16. Install the pressure switch assembly that was removed in Step 11 to location (N). Tighten to a specified torque of 29 +/- 3 N.m.

Image1.8.1

Image1.8.2

17. Install the valve body and clip with the four bolts which were removed in Step 10. Tighten to a specified torque of 55 +/- 10 N.m.

Refer to Step 19 for the harness installation.

Image1.9.1

18. Route the unconnected harness to back side of the plate. Refer to Detail C. Refer to Image1.10.1 and 1.10.2.

Image1.10.1

Image1.10.2

19. Connect 319-4407 Pressure Switch Assembly (F) (Cab upper side "A") to the connector (orange and yellow harnesses) and 319-4407 Pressure Switch Assembly (F) (Cab bottom side "B") to the connector (orange and blue harnesses). Refer to Step 8. Refer to Image1.11.1 and 1.11.2.

20. Secure the harnesses with 7K-1181 Cable Straps (P) and 3S-2093 Cable Straps (R).

NOTE: Avoid interference between the plate edge and the harness.

Image1.11.1

Image1.11.2

21. Remove cable straps (S). Refer to Image1.12.1.

22. Remove harness connectors (T).

23. Remove protector (U).

Note: Retain protector (U) and the bolts for later reuse.

Image1.12.1

24. Tighten up 489-4253 Harness Assembly (V) with 7K-1181 and 204-1611 Cable Straps. Refer to Image1.13.1.

Image1.13.1

25. Connect 489-4253 Harness Assembly (V) and the unconnected harness at the boom foot with 116-0118 Clip (W). Tighten to a specified torque of 55 +/- 10 N.m. Refer to Image1.14.1.

Image1.14.1

26. Install 130-5301 Clip (X) on the protector. Tighten to a specified torque of 100 +/- 20 N.m. Refer to Image1.15.1.

Image1.15.1

27. Reinstall protector (U) with the bolts. Refer to Image 1.16.1.

M10: Tighten to a specified torque of 55 +/- 10 N.m.
M12: Tighten to a specified torque of 100 +/- 20 N.m.

28. Reinstall harness connectors (T).

29. Tighten up the harness with 204-1611 Cable Strap (Y).