PRODUCT SUPPORT PROGRAM FOR REWORKING THE 107-4376 HYDRAULIC TANK BOSS ON CERTAIN 559C, 2384C, AND 579C KNUCKLEBOOM LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 107-4376 HYDRAULIC TANK BOSS ON CERTAIN 559C, 2384C, AND 579C KNUCKLEBOOM LOADERS

Usage:

TEBE0487-00

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11Nov2013

U-553

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 107-4376 HYDRAULIC TANK BOSS ON CERTAIN 559C, 2384C, AND 579C KNUCKLEBOOM LOADERS
5056 1408		PS44077

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44077" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

30Nov2015

PROBLEM

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The existing 107-4376 Hydraulic Tank Boss can interfere with 213-0677 Level Sensor on certain 559C, 2384C, and 579C Knuckleboom Loaders. If the existing boss is not reworked it can cause the hydraulic oil level sensor to display false low readings to the operator.

AFFECTED PRODUCT

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Model	Identification Number
2384C	KAW00251
559C	KAS00254-00256
579C	KAX00254-00255

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

The tool required for this Rework Procedure must be ordered from:

Robert Shelly
email: shelly_robert_a@cat.com or
work phone: (715) 428-1256

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

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NOTE: This is a 6.0-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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1. Follow all safety practices outlined in the machines Operation and Maintenance Manual before performing any work to the machine.

2. Clean areas around the hydraulic clean out cover and the hydraulic oil level sensor prior to performing any work.

3. Drain the hydraulic oil from the tank as outlined in SEBU8706, Operation and Maintenance Manual. Retain the hydraulic oil in a suitable and clean container for later reuse.

4. Remove the six bolts that retain the clean out cover to the bottom of the hydraulic tank. Refer to Image1.1.1.

Image1.1.1

5. Remove the 213-0677 Sensor from the engine side of the hydraulic tank. Refer to Image1.2.1.

Image1.2.1

6. Insert the cutting tool and attach a drill as shown in Image1.3.1.

IMPORTANT: The cutting tool will only cut in one direction.

Image1.3.1

7. If available, use magnets to help collect any debris created while reworking the boss. You may also want to apply grease the cutting tool to aid in collecting shavings and also to lubricate the tool while cutting. Refer to Image1.4.1.

8. While pulling back, operate the drill slowly and cut the threads of the hydraulic oil level sensor boss. The end of the cutting tool will only allow you to cut to the proper depth. You will need to completely bottom the tool in the boss to ensure all of the threads have been removed that could interfere with the float of the sensor.

Image1.4.1

9. Once you have removed the threads from the boss reinstall the level sensor and ensure that the float of the sensor is able to move freely when installed.

10. Completely clean the hydraulic tank from any contamination. Wipe clean with a good solvent and clean rags. Ensure the tanks walls, clean out cover, and baffles are cleaned before installing the clean out cover.

11. Apply Loctite 404 to the threads of the cover's retaining bolts and install the cover. Tighten the six bolts to a specified torque of 3 Ft/lbs.

12. Refill the hydraulic tank and ensure there are no leaks.