PRODUCT SUPPORT PROGRAM FOR INSPECTION, PLUGGING, AND DRILLING OF DRAIN HOLES IN THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTION, PLUGGING, AND DRILLING OF DRAIN HOLES IN THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS

Usage:

TEBE5426-01

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07Nov2016

(Revised 14Nov2016)

U-587

A-419

O-491

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSPECTION, PLUGGING, AND DRILLING OF DRAIN HOLES IN THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS
6501		PS45272

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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 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 "PS45272" 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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NOTE:	This Revised Service Letter replaces the 07Nov2016 Service Letter. Changes have been made to Parts Needed. The 5135090/">513-5090 Plugs-Boom are needed both Before and After Failure.

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TERMINATION DATE

30Nov2018

PROBLEM

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Certain TL1055D and TL1255D Cat Telehandlers may experience a water buildup in the internal cavity around the boom pivot shaft of the Base Boom Assembly. If the ambient temperature stays below freezing, water that accumulates in this cavity is subject to freezing, causing the boom pivot gusset plates to bulge, and in some cases, crack around the weld.

AFFECTED PRODUCT

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Model	Identification Number
TL1055D	ML500150-00639 MNT00150-00167
TL1255D HRC	ML700150-00618
TL1255D LRC	MYW00150-00156

PARTS NEEDED

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Qty	Part Number	Description
3	5135090	PLUG-BOOM
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 11% 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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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%
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-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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Note: Locally source 3 ounces of clear silicone, Dow Corning 700 Industrial Grade or equivalent, for use in Step 3.

- Park machine on a firm level surface, level the machine, extend boom to section A, raise boom for access, place transmission in (N) NEUTRAL, engage park brake, and shut engine OFF.
- Place a Do Not Operate Tag on both the ignition key and steering wheel.
- Properly support boom.
- Open engine cover. Allow the system fluids to cool.
- Properly disconnect the battery.

BOOM PIVOT PLUG INSTALLATION

1. Refer to Image1.3.1 and Image1.3.2. Remove and retain the rear boom cover plate (100) and hardware.

Note: If the boom pivot plugs are already installed, proceed to step 5.

Image1.3.1

Image1.3.2

2. Clean the boom holes (101) and surrounding area at the rear of the first boom section. Verify all holes are clean and free of any cleaning residue.

3. Refer to Image1.4.1. Apply clear silicone sealant, Dow Corning 700 Industrial Grade or equivalent, completely filling the upper cavity of the three Plugs (2) P/N 5135090/">513-5090.

Image1.4.1

4. Refer to Image1.5.1 and Image1.5.2. Install Plugs (2) in each of the three boom holes. Drive each Plug (2) flush with the top of the boom plate. Clean any excess silicone from around each plug.

Image1.5.1

Image1.5.2

DRILLING BOOM PIVOT GUSSET PLATES

Note: If boom pivot gusset plate holes already exist, proceed to step 7.

5. Refer to Image1.6.1 and Image1.6.2. Mark and drill one 0.250 inch hole (102) centered in each boom pivot gusset plate 0.625 inch above the bottom weld seam (103). De-burr, clean, and paint any bare metal.

Image1.6.1

Image1.6.2

6. Refer to Image1.6.1 and Image 1.7.1. Mark and drill one 0.250 inch hole (104) as close to centered as possible in the two outside boom gusset plates, 1.250 inch above the bottom weld seam (105).

Note: Do not drill any closer than 0.625 inch from the left edge of the left boom plate (106). De-burr, clean, and paint any bare metal.

Image1.7.1

BOOM PIVOT GUSSET PLATE INSPECTION

7. Refer to Image1.8.1 and Image1.8.2. Inspect the three rear boom pivot gusset plates (107) and the three front boom pivot plates (108) for any cracked welds, bulging or deformed gusset plates from the result of freezing.

Image1.8.1

Image1.8.2

8. If any deformities or cracked welds are found, record the letter designation of the plate. These are the plates that will have to be ordered for the following After Failure Service Letter, TEBE5430, "PRODUCT SUPPORT PROGRAM FOR REPLACEMENT OF THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS".

NOTE: If ONLY the rear plates A or B (107) are deformed or have cracked welds, After Failure Service Letter, TEBE5430, "PRODUCT SUPPORT PROGRAM FOR REPLACEMENT OF THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS" can be performed in the field with the proper repair tooling and qualified welder. If the front plates C or D (108) are deformed or have cracked welds, the machine will have to be transported to a repair facility with a 10,000 pound capacity hoist or crane and the boom assembly removed in order to complete After Failure Service Letter, TEBE5430, "PRODUCT SUPPORT PROGRAM FOR REPLACEMENT OF THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS".

NOTE: If there are front and rear boom gusset plates that require replacement, it is best done with the boom removed from the machine.

9. If no deformities or cracks are found, enter that comment in the story portion of the warranty claim.

10. Remove the boom support.

11. Properly connect the battery.

12. Close and secure the engine cover.

13. Remove the Do Not Operate Tag on both the ignition key and steering wheel.

14. Return the machine to service.