PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE 453-0305 BAR ASSEMBLIES ON CERTAIN PL72 PIPELAYERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE 453-0305 BAR ASSEMBLIES ON CERTAIN PL72 PIPELAYERS

Usage:

TEBE9176-00

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20May2019

U-293

O-259

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE 453-0305 BAR ASSEMBLIES ON CERTAIN PL72 PIPELAYERS
7051 7150		PI33025

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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 "PI33025" 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 "PI33025" 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
30Nov2019	31May2020

PROBLEM

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The bolted joint that attaches the 453-0305 Bar Assembly to the main frame, could have contact between the 1498857/">149-8857 spacer and the welded gusset on the 453-0305 Bar Assembly. If contact occurs, it may prevent the bolt from being properly tightened and could potentially result in bolt loosening. Existing 453-0305 Bar Assemblies should be inspected for contact between the 1498857/">149-8857 spacer and toe of the gusset plate weld and replaced if necessary.

AFFECTED PRODUCT

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Model	Identification Number
PL72	P7200120-00137 P7300121-00126, 128-132

PARTS NEEDED

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Qty	Part Number	Description
32	1146099	BOLT-HEX HEAD (After Failure Only)
32	1498857	SPACER (After Failure Only)
2	5527188	BAR AS (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.

NOTE: Thirty-two M24 Bolts will need to be tightened to a torque of 900 Nm +/- 100 Nm (664 lb-ft +/- 75 lb-ft). This applied torque range may require a torque multiplier, hydraulic torque wrench, or equivalent wrench.

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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 1.0-hour job
NOTE: The 1.0 hour listed above is to perform the inspection. If any contact between the spacer and weld toe are found during the inspection, an additional 7.0 hours will be allowed to remove two existing 453-0305 Bar Assemblies and replace with two 552-7188 Bar Assemblies.

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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 INSPECTING THE 453-0305 BAR ASSEMBLIES ON CERTAIN PL72 PIPELAYERS

MODELS INVOLVED - PL72 Pipelayers

Dear Cat Product Owner:

The bolted joint that attaches the 453-0305 Bar Assembly to the main frame, could have contact between the 1498857/">149-8857 Spacer and the welded gusset on the 453-0305 Bar Assembly. If contact occurs, it may prevent the bolt from being properly tightened and could potentially result in bolt loosening. Existing 453-0305 Bar Assemblies should be inspected for contact between the 1498857/">149-8857 Spacer and toe of the gusset plate weld. If contact is found, the 453-0305 Bar Assembly will need to be replaced. 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 20May2019 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 20May2019 Service Letter

Rework Procedure

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1) Park machine on solid surface and prepare for rework.

2) Inspect the bolted joint that attaches the 453-0305 Bar Assembly to the main frame for contact between the spacers and the toe of the gusset weld as shown in Image 1.1.1, 1.1.2, and 1.1.3.

NOTE: Image 1.1.2 shows an example of NO contact between the spacers and toe of the gusset weld.

NOTE: Image 1.1.3 shows an example of contact between the spacers and toe of the gusset weld.

Image1.1.1

Image1.1.2

Image1.1.3

If none of the spacers are contacting the toe of the gusset weld, no additional actions are required.

If any of the spacers are contacting the toe of the gusset weld, the remainder of this Rework Procedure should be completed.

3) Retract Counterweights and secure with counter weight shipping pin or bolt. Lower boom onto supports that are resting on a solid surface. Ensure the boom is properly supported with blocking or equivalent. Leave slack in boom cables.

Image1.2.1

4) Locate one 25 Ton Lift Stand (9U-7540 or equivalent) under the left side of the tractor main frame formed plates as shown in Image 1.3.1 and Image 1.3.2.

NOTE: Do NOT locate the jack on the front bumper or the bottom guard.

Image1.3.1

Image1.3.2

5) Remove 7X-0851 Nuts, 8T-0364 Bolts, 6V-8237 Washers, and 380-7460 Guards from Hand Bar assembly on the left hand side of the tractor.

NOTE: This hardware will be reused.

Image1.4.1

6) Apply force to the main frame with the 25 Ton Lift Stand (9U-7540 or equivalent). Do NOT apply any force greater than the force required to separate the Hard Bar Pin from the Roller Frame Ear by 3 to 5 millimeters as shown in Image 1.5.1.

NOTE: The track shoe grousers should remain in contact with the ground. Do NOT lift the track shoe grouser off the ground.

Image1.5.1

7) Secure the locking ring on 25 Ton Lift Stand (9U-7540 or equivalent) in order to turn the jack into a jack stand. Then remove existing 114-6099 Bolts, 1498857/">149-8857 Spacers, and 453-0307 Bar Assembly on the left hand side of the tractor. The existing hardware and bar assembly should be discarded.

Image1.6.1

8) Remove existing 281-4015 Pin from 453-0307 Bar Assembly. The existing 281-4015 Pin will be reused.

Image1.7.1

9) Install existing 281-4015 Pin in 552-7188 Bar Assembly.

10) Install existing 281-4015 Pin and 552-7188 Bar Assembly on left hand side of tractor using new 114-6099 Bolts and 1498857/">149-8857 Spacers. The 114-6099 Bolts should be tightened to a torque of 900 Nm +/- 100 Nm (664 lb-ft +/- 75 lb-ft).

Image1.8.1

11) After all bolts have been torqued in Step 10, remove pressure from 25 Ton Lift Stand (9U-7540 or equivalent) and lower the main frame so the Pin completely contacts the Roller Frame as shown in Image 1.9.1. Install 7X-0851 Nuts, 8T-0364 Bolts, 6V-8237 Washers, and 380-7460 Guards from Hand Bar assembly on the left hand side of the tractor and tighten the bolts to a torque of 900 Nm +/- 100 Nm (664 lb-ft +/- 75 lb-ft).

Image1.9.1

12) After Steps 4 through Step 11 have been completed on the left hand side of the tractor, repeat Steps 4 through Step 11 on the right hand side of the tractor. The 25 Ton Lift Stand (9U-7540 or equivalent) should be located under the tractor main frame on the right side of the main frame formed plates as shown in Image 1.10.1 and Image 1.10.2.