PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER ON CERTAIN TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, AND TH580B TELEHANDLERS; AND ON CERTAIN CIPI POWER MODULES Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER ON CERTAIN TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, AND TH580B TELEHANDLERS; AND ON CERTAIN CIPI POWER MODULES

Usage:

REBE2573-02

22Jan2008
(Revised 10Apr2008)


U-39
A-35
D-31
O-35

 
After Failure Only
  
  

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER ON CERTAIN TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, AND TH580B TELEHANDLERS; AND ON CERTAIN CIPI POWER MODULES

3101 5068
PS51434
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 "PS51434" 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.

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.

 
NOTE:

This Revised Service Letter replaces the 22Jan2008 (Revised 28Jan2008) Service Letter. Changes have been made to the Service Claim Allowance and Rework Procedure notes.


TERMINATION DATE

31Jan2010

PROBLEM

The existing torque converter can fail on certain TH220B, TH330B, TH340B, TH350B, TH355B, TH360B, TH460B, TH560B, and TH580B Telehandlers; and on certain CIPI Power Modules. If the existing torque converter fails it will result in a loss of power. Installation of the new torque converter will prevent repeat failures.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
TH220B  SLA00250-00264, 266-270, 272-739, 850-1130
TH330B  SLB00250-01366, 1500-2009
TH340B  SLC00250-00253, 255-352, 700-772, 850-873
TH350B  SLD00250-00251, 254-531, 600-755, 1000-1258, 1400-1640
TH355B  JRK00100-00177, 450-591
TH360B  SLE00250-00258, 266-1264, 1350-1898, 3000-4043, 4500-5485
TH460B  SLF00250-00804, 900-1893, 2100-2871, 6423
TH560B  SLG00250-01171, 1300-1688
TH580B  SLH00250-00720, 900-1264
*******Group  2*******
PM OEM  MLS00101-00596, 598-603, 605-610, 613-930, 932-937, 941-945, 948-953, 956-996, 998-1001, 1003-1347, 1349-1385, 1387-1397, 1400-1496, 1498-1686, 1688-1708, 1710-1720, 1722, 1724-1733, 1735-1772, 1775-1805, 1807-1853, 1855, 1857-1860, 1862-1970, 1973-1982, 1984-1992, 1994-2001, 2004-2010, 2013-2018, 2024-2027, 2033, 2035-2036, 7531, 7594

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 1G8878 FILTER AS-HYD
8 1076826 BOLT-12 POINT HD
1 1788164 SEAL-OIL
1 2935003 TC GP-BASIC
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.
*******Group 2*******
1 1G8878 FILTER AS-HYD
8 1076826 BOLT-12 POINT HD
1 1788164 SEAL-OIL
1 2935003 TC GP-BASIC
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

See attached rework procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs,
25-48 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 10.0-hour job for Group 1
Note: An additional 25 hours of labor to flush and clean the oil system can be claimed if there was a major failure that sent debris through the system. The filter should be cut open and an SOS sample taken to confirm debris is present. The SOS report should be attached to the warranty claim when filing for the additional labor.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs,
25-48 mo 
33.3%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 10.0-hour job for Group 2
Note: An additional 25 hours of labor to flush and clean the oil system can be claimed if there was a major failure that sent debris through the system. The filter should be cut open and an SOS sample taken to confirm debris is present. The SOS report should be attached to the warranty claim when filing for the additional labor.



PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
 


Rework Procedure


 
Replace the failed 2307551 Torque Converter using the following procedure for both Group 1 and Group 2.

NOTE: Cat Branded JLG Telehandler Serial Numbers.
These serial numbers are for reference ONLY, DO NOT use for filing warranty claims
The Power Module serial numbers (MLS prefix) MUST be used for warranty claims.

TH220B
TBF00100-00124, 126-141, 143-268, 270, 272-285, 287-339, 341-343, 345-347, 349-378,
383, 384, 387-390, 393, 397, 399

TH330B
TBG00100-00113, 115-187, 189-196, 199-382, 384, 386-400, 402-426, 428-437, 439, 441,
442, 445-511, 513-587, 589-617, 619-622, 625, 629-631, 633-640, 642, 660, 664

TH360B
TBH00100-00102, 104-133, 135-139, 141-227, 229-560, 562-645, 647-689, 691-694, 696-802, 804-809, 811-818, 820-823, 825-839, 841-846, 848-855, 857, 858, 862, 879

TH560B
TBP00100-00108, 110-151, 153-160, 162-174, 178, 179, 182

TH580B
TBJ00101-00114, 116-206, 208-213, 215-248, 250-255, 257-272, 274, 275, 277-280, 282-284, 286-310, 312, 313, 315-317,319-323, 326, 327, 329, 332, 335, 340, 390

Refer to the Service Manuals as necessary.
RENR5186, Disassembly and Assembly Manual TH350B, TH355B, TH360B, TH460B, TH560B Telehandler Power Train.
RENR7706, Disassembly and Assembly Manual TH220B and TH330B Telehandler Power Train.
RENR7755, Disassembly and Assembly Manual TH580B Telehandler Power Train.
 
1. Remove the transmission and torque converter from the machine and then remove the converter from the transmission.
2. Install a new 1788164 Lip Seal.
3. Install the new 2935003 Torque Converter.
4. Install the transmission and torque converter into the machine.
5. Use new 1076826 Bolts to install the front and rear drive shafts to the transmission.
6. Install a new 1G8878 Power Train Oil Filter.
7. Test the machine for proper operation.
 
 

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