PRODUCT SUPPORT PROGRAM FOR REPLACEMENT OF THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACEMENT OF THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS

Usage:

TEBE5430-00

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07Nov2016

U-586

A-418

D-493

O-490

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACEMENT OF THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS
6501		PS53339

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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 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 "PS53339" 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

30Nov2018

PROBLEM

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While conducting Service Letter TEBE5426, "PRODUCT SUPPORT PROGRAM FOR INSPECTION, PLUGGING, AND DRILLING OF DRAIN HOLES IN THE BOOM PIVOT GUSSET PLATES ON CERTAIN TL1055D AND TL1255D CAT TELEHANDLERS", certain TL1055D and TL1255D Caterpillar Telehandlers were identified with bulging boom pivot gusset plates and/or cracked welds. These plates must be replaced.

Group 1 - Are those machine serial numbers that require just one or more of the rear boom pivot gusset plates to be replaced.

Group 2 - Are those machine serial numbers that require one or more of the front as well as a rear boom pivot gusset plate to be replaced.

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
2	3235623	NIPPLE, Item 105, Group 1 and 2
1	5135082	PLATE-BOOM, 106 (A), As Required, Group 1 and 2
1	5135083	PLATE-BOOM, 106 (B), As Required, Group 1 and 2
1	5135086	PLATE-BOOM, 119 (C), As Required, Group 2 Only
1	5135087	PLATE-BOOM, 119 (D), As Required, Group 2 Only
3	5135090	PLUG-BOOM, Item 115, Group 2 Only
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 5.5-hour job
Group 1: This is a 5.5 hour job. NACD and LACD: Travel Time and Mileage up to 3 hours OR machine hauling up to $500 Group 2: This is a 16 hour job. NACD and LACD: Machine hauling up to $500.

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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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REQUIRED TOOLS:
? Stands and lifting equipment capable of lifting / supporting the affected components
? Hand held power grinder
? Air carbon-arc equipment
? Electric welding equipment
? AWS 70 grade, low hydrogen rod or wire
? Standard welding tools
? Standard mechanic tools
? CAT Yellow Paint

PERSONNEL REQUIRED
? Qualified Equipment Technician
? Certified Welder

WELD REPAIR GUIDELINES
? All welding must be in strict accordance with ANSI/AWS D1.1 standards
? Ground only to the components being welded. DO NOT ground to any adjacent component or allow pins, wear pads, wire ropes, bearings, seals, valves, electrical wiring, or hoses to be between the grounding position and the area being welding.
? Failure to comply with the above weld repair guidelines may result in component damage.

GROUP 1: REAR BOOM PIVOT GUSSET PLATE ONLY

PROCEDURE:
- Park the machine on a firm, level surface, level the machine, extend the boom until Section A of the Boom Extension Indicator is completely visible, lower the boom, place the transmission in (N) NEUTRAL, engage park brake and shut off engine.
- Place a Do Not Operate Tag on both the ignition key-switch and steering wheel.
- Open the engine cover. Allow the system fluids to cool.
- Properly disconnect the battery.

1. Refer to Image1.4.1 and Image1.4.2. Remove and retain hardware, rear boom cover plate (100) and frame rear panel (101).

Image1.4.1

Image1.4.2

2. Label and disconnect all electrical connections to the boom assembly.

3. Refer to Image1.6.1. At the rear side of the boom (104), remove and retain nut (102) from grease hose (103) and lay to the side.

Image1.6.1

4. Protect all wear pads, hydraulic hoses and valve near the rear of the boom pivot gusset plates with appropriate welding blankets before repair.

5. Refer to Image1.8.1. Grease fittings (105) must remain in place during the rework and replaced after the rear boom pivot gusset plate installation.

Image1.8.1

6. Taking extreme caution not to damage the parent metal, using air carbon-arc equipment, remove all affected rear boom pivot gusset plate(s) (106).

7. Grind the edges of the cut out where the affected boom pivot gusset plate(s) (106) were removed. Thoroughly clean the area. (i.e., dirt, grease, rust, paint, etc.)

WELD DETAILS CAN BE FOUND IN IMAGE1.15.1 AT THE END OF GROUP 1 INSTRUCTIONS

8. Refer to Image1.11.1 and Image1.15.1. Place and weld the appropriate rear boom pivot gusset plate (106) on the rear side of boom (104). Ensure drain hole (107) is oriented to the bottom.

Image1.11.1

9. Inspect welds using the magnetic particle or dye-penetrant inspection methods to assure there are no cracks or deformities. If any cracks or deformities exist, grind to remove affected area and repeat the weld and inspection procedures.

10. Mask the surfaces or parts which are unaffected before painting.

11. Clean, prime and paint the affected areas.

12. Refer to Image1.13.1. Remove and discard existing grease fittings (105) from the rear side of the boom (104). Replace with new.

Image1.13.1

13. Reconnect grease hose (103) that was moved out of the way in Step 3, with nut (102), to the rear side of the boom (104).

14. Connect all electrical connections to the boom that were disconnected in Step 2.

15. Reinstall the rear frame cover (101) and rear boom cover (100), that were removed in Step 1.

16. Properly connect the battery.

17. Close and secure the engine cover.

18. Remove Do Not Operate Tag from both the ignition key switch and steering wheel.

19. Return to service.

REAR BOOM PIVOT PLATE WELDMENT

Image1.15.1

GROUP 2: FRONT AND REAR BOOM PIVOT GUSSET PLATES (COMPLETE BOOM ASSEMBLY REMOVAL REQUIRED)

Note: When removing the complete boom assembly use a hoist or crane with a minimum lift capacity of 10,000 lb (4536 kg).

Note: Locally source 3 ounces of clear silicone, Dow Corning 700 Industrial Grade or equivalent, for use in Step 37.

PROCEDURE:
- Remove any attachment from the quick coupler assembly. Refer to Operation & Safety Manual
- Remove the quick coupler assembly. Refer to the appropriate Service Manual.
- Park the machine on a firm level surface, extend boom until Section A of the Boom Extension Indicator is completely visible, approximately 22 in. (558.8 mm) as measured from the back of the second section to the back of the first section. Raise the boom assembly to access lift/lower cylinder pin and the compensation cylinder pin.
- Place the transmission in (N) NEUTRAL, engage the park brake and shut the engine off.
- Place a Do Not Operate Tag on both the ignition key-switch and steering wheel .
- Open the engine cover. Allow the system fluids to cool.
- Properly disconnect the battery.
- Close the engine cover to access lift/lower cylinder pin and the compensation cylinder pin.
- Place a sling around the first boom section and properly support the boom assembly with a hoist or crane.
- Remove the boom angle sensor arm at the rear of the boom assembly. Refer to the appropriate Service Manual.

1. Refer to Image1.19.1. Taking caution not to drop the cylinder, remove and retain the hardware and pin (108) from the rod end of the lift/lower cylinder. Lower the cylinder to a secure position.

Image1.19.1

2. Taking caution not to drop the cylinder, remove and retain the hardware and pin (109) from the rod end of the compensation cylinder. Lower the cylinder to a secure position.

3. Lower the boom assembly to a level position.

4. Refer to Image1.21.1. Label, disconnect, and cap the extend/retract cylinder hoses (111). Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

Image1.21.1

5. Label, disconnect, and cap the tilt cylinder hoses (112) and auxiliary hoses (113). Cap all fittings and openings to keep dirt and debris from entering the hydraulic system.

6. Label and disconnect all electrical connections to the boom assembly.

Note: Verify that the sling does not interfere with the extend/retract cylinder or any hydraulic tubes.

7. Confirm that the boom assembly is balanced with the sling, remove and retain the hardware and boom assembly pivot pin (110).

8. Lift the complete boom assembly from the machine, set on level ground or supports by repositioning the slings, turn boom over on the top side. Set the complete boom on suitable stands.

9. Ensure that both front and rear boom pivot gusset plates are accessible for welding from the top.

Note: Properly protect the components near the rear of boom pivot gusset plates with welding blankets before making repair.

10. Refer to Image1.23.1. Grease fittings (105) must remain in place during the rework and replaced after the rear boom pivot gusset plate installation.

Image1.23.1

11. Taking extreme caution not to damage the parent metal, using air carbon-arc equipment, remove all affected rear boom pivot gusset plate(s) (106), from the rear side of the boom (104).

12. Grind the edges of the cut out where the affected boom pivot gusset plate(s) (106) were removed. Thoroughly clean the area. (i.e., dirt, grease, rust, paint, etc.)

13. Refer to Image1.25.1. Remove and discard the plugs (115) from the three boom holes, if installed.

Image1.25.1

14. Refer to Image1.26.1. Properly protect all extend/retract chains, wear pads, electrical and hydraulic connections inside of the boom with appropriate welding blanket (116).

Image1.26.1

15. Refer to Image1.27.1. Using metal cutting tools, remove and retain the hose guides (118a and b) from the front side of the boom (117).

Image1.27.1

16. Refer to Image1.28.1. Taking extreme caution not to damage the parent metal, using air carbon-arc equipment, remove all affected front boom pivot gusset plate(s) (119), from the front side of the boom (117).

Image1.28.1

17. Grind the edges of the cut out where the affected boom pivot gusset plate(s) (119) were removed. Thoroughly clean the area. (i.e., dirt, grease, rust, paint, etc.)

WELD DETAILS CAN BE FOUND IN IMAGE1.37.1 AND IMAGE1.38.1 AT THE END OF GROUP 2 INSTRUCTIONS

18. Refer to Image1.31.1 and Image1.37.1. Place and weld the appropriate rear boom pivot gusset plate (106) on the rear side of boom (104). Ensure drain hole (107) is oriented to the top.

Image1.31.1

19. Inspect welds using the magnetic particle or dye-penetrant inspection methods to assure there are no cracks or deformities. If any cracks or deformities exist, grind to remove affected area and repeat the weld and inspection procedures.

20. Mask the surfaces or parts which are unaffected before painting.

21. Clean, prime and paint the affected areas.

22. Refer to Image1.33.1. Remove and discard existing grease fittings (105) from the rear side of the boom (104). Replace with new.

Image1.33.1

23. Refer to Image1.34.1 and Image1.37.1. Place and weld the appropriate front boom pivot gusset plate (119) on the front side of boom (117). Ensure drain hole (107) is oriented to the top.

Image1.34.1

24. Refer to Image1.35.1 and Image1.38.1. Weld hose guides 118a & 118b on the front of the boom (117).

Image1.35.1

25. Inspect welds using the magnetic particle or dye-penetrant inspection methods to assure there are no cracks or deformities. If any cracks or deformities exist, grind to remove affected area and repeat the weld and inspection procedures.

26. Mask the surfaces or parts which are unaffected before painting.

27. Clean, prime and paint the affected areas.

Front and Rear Boom Pivot Plate Weldment

Image1.37.1

Hose Guide Weldment

Image1.38.1

28. Using suitable slings and a hoist or crane with a minimum lift capacity of 10,000 lb (4536 kg), turn boom over to the bottom side by repositioning the slings and set on level ground or supports.

Note: Verify that the sling does not interfere with the extend/retract cylinder or any hydraulic tubes.

29. Refer to Image1.40.1. Using slings, balance the boom assembly, lift and carefully guide the boom into place. Align the frame pivot bores with the boom assembly pivot bores. Install boom pivot pin (110) and lock bolt.

Image1.40.1

30. With the sling still in place, install the compensating cylinder pin, (109) and lock bolt.

31. With the sling still in place, install the lift/lower cylinder pin, (108) and lock bolt.

32. Refer to Image1.41.1. Uncap and connect the previously labeled extend/retract cylinder hoses (111) to the appropriate tube connection.

Image1.41.1

33. Uncap and connect the previously labeled tilt hoses (112) and auxiliary hoses (113) to the appropriate tube connection.

34. Connect all electrical connections to the boom assembly.

35. Refer to the appropriate Service Manual, install the boom angle sensor rod. The sensor will require re-calibrating before the machine is placed back in service.

36. Remove slings and supports.

37. Refer to Image1.42.1 and Image 1.42.2. Clean the boom holes (120), and surrounding area at the rear of the first boom section. Verify all holes are clean and free of any cleaning residue. Apply Silicone, Dow Corning 700 Industrial Grade or equivalent, completely filling the upper cavity (1) of the three Boom plugs (115) P/N 513-5090.

Image1.42.1

Image1.42.2

38. Refer to Image1.43.1 and Image1.43.2. Install Plugs (115) in each of the three boom holes. Drive each Plug (115) flush with the top of the boom plate. Clean any excess silicone from around each plug.

Image1.43.1

Image1.43.2

39. Properly connect the battery.

40. Start the engine and operate all of the boom functions several times, ensure proper operation.

41. Retract and lower the boom assembly and shut off engine.

42. Check for fluid leaks. Check the hydraulic fluid level in the tank and add as required.

43. Clean up all debris, hydraulic fluid, etc., in, on, near and around the machine.

44. Remove the Do Not operate Tag from both the ignition key switch and the steering wheel.

45. Return the machine to service.