PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXTEND CHAIN PIN AND FUSE PANEL DECALS

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXTEND CHAIN PIN AND FUSE PANEL DECALS - MULTIPLE REPAIRS

Usage:

TEBE4398-00

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10Jun2016

U-306

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE EXTEND CHAIN PIN AND FUSE PANEL DECALS - MULTIPLE REPAIRS
6460 6501 7405		PI32642

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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 "PI32642" 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 "PI32642" 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
31Dec2016	30Jun2017

PROBLEM

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The affected telehandlers may experience deformation of the Sheave Wheel Pin Keeper Plate due to high friction between the pin and sheave wheel. In some cases the keeper plate bolts have also broken. The same machines also requires fuse panel decals to be updated.

AFFECTED PRODUCT

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Model	Identification Number
TL1055D	ML500155-00232, 235-240, 242-243, 246-250, 252, 256-257, 260, 281-283, 285-286, 294-297, 299
TL1255D HRC	ML700160-00175, 178-193, 195-200, 202-219, 221-223, 264

PARTS NEEDED

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Qty	Part Number	Description
2	5M2894	WASHER-HARD
2	8T1158	BOLT-SOCKET HD
1	4741582	PIN
1	4809877	FILM
1	4809880	FILM
1	4963469	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 43% 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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If service letter CAT1512 has already been performed, enter a SIMS report with a 'NA' or 'NI' description code. If Service Letter CAT1512 has been previously performed, do NOT complete this Service Letter program.

If service letter CAT1512 has not been performed, 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 3.0-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.

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 REPLACING THE EXTEND CHAIN PIN AND FUSE PANEL DECALS - MULTIPLE REPAIRS

MODELS INVOLVED - TL1055D AND TL1255D TELEHANDLERS

Dear Cat Product Owner:

The extend chain pin and two fuse decals need to be replaced on the products listed below. The existing extend chain pin can cause deformation of the sheave wheel pin keeper plate due to high friction between the pin and sheave wheel. Two fuse panel decals also need replacement. 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 10Jun2016 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 10Jun2016 Service Letter

Rework Procedure

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Preparation for Rework:

- Park the machine on a firm, level surface and level the machine.
- Deploy the outriggers and position the boom to a safe workable height, accessible while standing on the ground. Properly support the boom.
- Extend the boom to the boom length "C" indicator. Then retract it to the "B" length indicator.
- Place the travel select lever in the (N) NEUTRAL position, and shut the engine OFF.
- Use wheel chocks to prevent the machine from moving.
- Remove the key from the MAIN switch located inside the engine compartment.
- Properly disconnect the battery.
- Place a Do Not Operate Tag on both the ignition key-switch and the steering wheel.

Note: Use all applicable safety precautions while working on, around, or under any machinery.

1. Locate extend chain adjusting nuts (A) and the extend chain sheave pin and retaining hardware (B). Refer to Image1.2.1.

2. Loosen extend chain adjusting nuts (A).

Image1.2.1

3. Remove two existing extend chain sheave retaining pin bolts (C), two washers (D), and retaining plate (E). The two extend chain sheave retaining pin bolts (C) will not be reused. Refer to Image1.3.1.

Image1.3.1

4. Prior to installation of new 474-1582 Pin (1), coat the surface with lithium grease. Refer to Image1.4.1.

5. Using a dead blow hammer, ensure that the new pin is properly oriented and use the new pin to drive the old pin out.

Image1.4.1

6. Position new 496-3469 Pin Retainer (4). Refer to Image1.5.1.

7. After applying thread locking compound Loctite 242 to two 8T-1158 Socket Head Cap Screws (2) and two 5M-2894 Hardened Washers (3). Install and tighten the cap head socket screws to a specified torque of 21 lb-ft (29 N.m).

Image1.5.1

8. Remove grease fitting (F) from the old pin. The old pin will not be reused. Install the grease fitting to the new pin. Refer to Images1.6.1 and 1.6.2.

Image1.6.1

Image1.6.2

9. Adjust the extend chain tension as described in UENR6276, Disassembly and Assembly, TL642D TL943D TL1055D TL1255D Service Manual.

10. Reconnect the battery and replace the key in the main switch.

11. Adjust the boom height to gain access to the Frame Power Distribution Board located in the center of the frame. Properly support the boom. Refer to Images1.7.1 and 1.7.2.

12. Remove the cover. Ensure that the inside of the cover is clean and dry. Mount new 480-9877 Film (5) over the existing decal.

13. Install the cover.

Image1.7.1

Image1.7.2

14. Remove the dash corner panel (G) to gain access to the cabin electronics. Refer to Images1.8.1 and 1.8.2.

15. Locate the fuse decal on the cab weldment. Ensure that the fuse decal is clean and dry. Mount a new 480-9880 Film over the existing fuse decal.

Image1.8.1

Image1.8.2

16. Retract the boom.

17. Retract the outriggers.

18. Remove the wheel chocks.

19. Remove all DO NOT OPERATE Tags.

20. Verify that the boom extends and retracts properly.

21. Place the machine back in to service.