PSP FOR INSTALLING NEW THROTTLE CONTROL CONSOLE PARTS THAT ARE MORE RESISTANT TO CRACKING ON CERTAIN CP643, CS643, CP653, AND CS6 53 COMPACTORS; AND CERTAIN ALBARET BUILT VM1203 AND VM1204 COMPACTORS - PS4518

PSP FOR INSTALLING NEW THROTTLE CONTROL CONSOLE PARTS THAT ARE MORE RESISTANT TO CRACKING ON CERTAIN CP643, CS643, CP653, AND CS6 53 COMPACTORS; AND CERTAIN ALBARET BUILT VM1203 AND VM1204 COMPACTORS - PS4518 - MAILED COSA

Usage:

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Caterpillar: Confidential Yellow

PSP FOR INSTALLING NEW THROTTLE CONTROL CONSOLE PARTS THAT ARE MORE RESISTANT TO CRACKING ON CERTAIN CP643, CS643, CP653, AND CS6 53 COMPACTORS; AND CERTAIN ALBARET BUILT VM1203 AND VM1204 COMPACTORS - PS4518 - MAILED COSA

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.


O-126
1265  PS4518
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the Program
is made by the dealer. When reporting the repair, use "PS4518"
as Part Number, "7755" as Group Number, and "96" as Description
Code.

Termination Date

August 31, 1991

Problem

Cracks may develop in the throttle control console of certain CP643, CS643,
CP653, and CS653 Compactors; and certain Albaret built VM1203 and VM1204
Compactors. New parts can be installed to make the console more crack
resistant.

Affected Product

Model Identification Number
CP643 7GD1-17
CS643 7FD47-60
CP653 7JD1-10, 13, 15, 16
CS653 7HD1-83, 85-90, 92
VM1203 940B71503, 71505, 71508-71511
VM1204 941B71501, 71506, 71507, 71518-71520

Parts Needed

1 - 5E7064 Cable
1 - 5E7065 Bracket Assembly
1 - 5E7083 Sheet
1 - 5H9743 Grommet
1 - 8M2770 Clip
1 - 7N8779 Gasket
1 - 5P3272 Seal
1 - 5P8167 Bolt
1 - 8T4896 Washer
1 - 6W1594 Plug
1 - 7W0735 Spring

Action Required

See the attached procedure.

Service Claim Allowances

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost)  (C/L) (Sell)
comes
first
0-3000 100% 5.5 0 0 0 0
0-36 mo
NOTE: This is a 5.5-hour job.
NOTE: When filing a claim for an Albaret built VM1203 or VM1204
Compactor, Use 99Z00019 as the Product Identification Number.
Enter the complete Albaret Product Identification Number
"941B........" in the "Related S/N Field".

Parts Disposition

Any parts removed (with the exception of cores used for Caterpillar
Remanufactured parts) can be rendered useless and scrapped immediately upon
completion of the repair.
Rework Procedure
1. Remove shroud (1), shroud (2), cover (3), and panel (4). See
Illustrations 1 and 2.
****** IMAGE: SEBE4380.00001.001
CAPTION: Illustration 1
****** IMAGE: SEBE4380.00001.002
CAPTION: Illustration 2
2. Remove washer reservoir (4) and two straps (5). Disconnect two hoses
(6). See Illustration 3.
****** IMAGE: SEBE4380.00001.003
CAPTION: Illustration 3
3. Remove door sill (7) and floor mat (8). See Illustration 4.
****** IMAGE: SEBE4380.00001.004
CAPTION: Illustration 4
4. Remove the existing cable as follows:
****** IMAGE: SEBE4380.00001.005
CAPTION: Illustration 5 - Engine Side
A) Remove nut (1) from ball joint (2)
B) Remove the ball joint from the cable
C) Remove nut (4) and remove the cable out of bracket (3)
****** IMAGE: SEBE4380.00001.006
CAPTION: Illustration 6 - Cab Side
D) Remove plate (1)
E) Remove nut (2) with a crowfoot wrench
F) Remove the clamping along the cable
G) Remove cable (3)
****** IMAGE: SEBE4380.00001.007
CAPTION: Illustration 7 - Location of Plug
H) Install the new 6W1594 Grommet (Plug) in the hole where the cable
was removed
I) Install plate (1) that was removed in Step D
5. Install the new 5E7064 Cable as follows:
****** IMAGE: SEBE4380.00001.008
CAPTION: Illustration 8 - Location of Existing Parts
A) Remove two existing nuts (2) holding bracket (3)
****** IMAGE: SEBE4380.00001.009
CAPTION: Illustration 9 - Install Bracket On Steering Column
B) If necessary, cut the insulation mat to make room for the new
bracket (1)
C) Install the new bracket (1) using two nuts (2) removed in Step A
****** IMAGE: SEBE4380.00001.010
CAPTION: Illustration 10 - Location of Hole
D) Drill a 22.5 mm dia hole in the floor plate at the location shown in
Illustration 10. Do not flame cut the hole
****** IMAGE: SEBE4380.00001.011
CAPTION: Illustration 11
E) Install the new grommet (5) in the drilled hole.
F) Remove the existing sheet (6) and install the new 5E7083 Sheet using
bolts (7)
G) Install the floor mat and door sill. Enlarge the existing hole in
the floor mat with a 12 mm dia drill by drilling through the
grommet.
****** IMAGE: SEBE4380.00001.012
CAPTION: Illustration 12
G) Install the new cable (8) on the bracket in the cab and through the
grommet.
H) Tighten two nuts (9)
I) Position the cable 20 mm out as shown and install nut (10) to hold
it
****** IMAGE: SEBE4380.00001.013
CAPTION: Illustration 13
J) Clamp the cable to the frame with the new clip, bolt, and washer
6. Install the new spring in the governor as follows:
****** IMAGE: SEBE4380.00001.014
CAPTION: Illustration 14
A) Remove support (2)
B) Remove governor lever (3)
****** IMAGE: SEBE4380.00001.015
CAPTION: Illustration 15
C) Remove cover (4)
****** IMAGE: SEBE4380.00001.016
CAPTION: Illustration 16
D) Remove two rings (5) and plate (6)
E) Replace the existing spring (1) shown in Illustration 15 with the
new 7W0735 Spring
F) Install the plate, rings, cover, lever, and cable support in their
original positions
G) Change the 7N8779 Gasket and 5P3272 Seal if necessary
7. Install and connect the cable as follows:
****** IMAGE: SEBE4380.00001.017
CAPTION: Illustration 17
A) Position the cable and secure with nuts (1)
B) Install ball joint (2) and nut (3) on cable (4)
C) Connect the ball joint to governor lever (5)
NOTE: Make sure the cable is still pulled out by 20 mm as shown in
Illustration 12. The cable must be pulled out 20 mm when the
lever is in the low idle speed position. When the cable handle
is pushed down the 20 mm stroke allows the engine to be stopped.
7. Test the engine and check to see if high idle speed, low idle speed, and
engine stop are possible.
8. Install the shrouds, cover, and panel previously removed.