A New Retaining Method Is Available For The Boom Pivot Pin On Certain Telehandlers{5456} Caterpillar

Telehandler:

TH220B (S/N: SLA1-UP)

TH330B (S/N: SLB1-UP)

TH340B (S/N: SLC1-UP)

TH350B (S/N: SLD1-UP)

TH355B (S/N: JRK1-UP)

TH360B (S/N: SLE1-UP)

TH460B (S/N: SLF1-UP)

TH560B (S/N: SLG1-UP)

TH580B (S/N: SLH1-UP)

Introduction

This Special Instruction details an improved method of retaining the boom pivot pin. In order to apply this new retaining method for the pin, a new retaining plate must be fabricated.

Proper Cleaning for Inspection

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

Before you inspect the area, clean the area with an appropriate high pressure washer. Be careful not to damage wires or other components. Use an appropriate degreaser to remove any oil or grease from the frame assembly. It may also be necessary to use a wire brush or a scraper to remove excessive dirt and grease. Make sure that the substances that follow are removed from the area that will be inspected.

• Oil

• Grease

• Dirt

Preparing the Area for Welding

Clean the area that will be welded. Make sure that the substances that follow are removed from the area that will be welded.

• Oil

• Grease

• Paint

• Dirt

If the temperature of the base metal is below 0 °C (32 °F), heat the base metal to a temperature of at least 21 °C (70 °F). Maintain the temperature of the base metal at 21 °C (70 °F) during the welding process.

Note: Heat distortion of the base metal is possible when you weld. Avoid excessive heating of the base metal.

Attach the welding ground cable directly to the base metal. Protect machined surfaces from sparks. Protect the machined surfaces from the weld splatter.

Weld Specifications and Qualifications

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Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can kill. Read and understand the manufacturer's instruction and your employer's safety practices. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing zone and the general area. Wear correct eye, ear and body protection. Do not touch live electric parts. Refer to the American National Standard Z49.1, "Safety in Welding and Cutting" published by the American Welding Society, 2501 N.W. 7th Street, Miami, Florida 33125: OSHA Safety and Health Standards, 29 CFR 1910, available from U.S. Dept. of Labor, Washington D.C. 20210.

Note: Personal breathing protection should be worn by the personnel that are welding. Personal breathing protection will prevent fumes from entering the lungs of the person that is welding. Use a 1U-8088 Type H Respirator for breathing protection.

Qualifications

Welders must be qualified for fillet welding and groove welding. The welders should be qualified in the use of the welding processes that follow: Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW) and Gas Metal Arc Welding (GMAW). Refer to "American National Standards Institute (ANSI)/American Welding Society (AWS) Specification D1.1, or Specification D14.3" for information that regards the qualifications for the processes that follow: SMAW process, FCAW process and GMAW process. The welders must have used the process at some time within the last six months. The welders must complete the process of certification if the welders have not used the welding processes for six months.

Proper Welding Procedure on Machines and Engines with Electronic Controls

Proper precautions are necessary to prevent damage to electronic controls. When you weld on a machine with electronic controls, use the steps that follow:

1. Turn off the engine. Put the key start switch in the OFF position.

2. If the machine has a battery disconnect switch, open the switch. If the machine does not have a battery disconnect switch, disconnect the negative battery cable at the battery.

3. Connect the ground cable for the welder directly to the actual machine component that will be welded. Attach the clamp for the ground cable as close as possible to the area that is being welded. This will reduce the chance of damage from welding current to the components that follow: bearings, hydraulic components and electrical components.

   Note: Do NOT use electrical components as a ground point for the welder. Do NOT use ground points for electronic components as a ground point for the welder.

Affected Machines

The following procedure is applicable to two different groups. Please consult table 1 for the correct group.

Required Parts

Installation Procedure

1. Park the machine on flat level ground. Lower the boom. Apply the parking brake. Turn the start key to the OFF position. Remove the key. Place wheel blocks in the front and in the back of the rear wheels.

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Illustration 1	g01619076
(A) centerline (B) 15 mm (0.60 inch) (C) 16.5 mm (0.65 inch) (D) 226 mm (8.9 inch) (E) 30 mm (1.2 inch) (F) 12 mm (0.47 inch) (G) 14 mm (0.55 inch) diameter

2. Fabricate the new retaining plate. Use BN EN 10025 S355 steel for the plate. Chamfer the corners of the plate to 5 mm (0.20 inch) at 45 degrees. See illustration 1.

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Illustration 2	g01619428
(A) 80 mm (3.15 inch)

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Illustration 3	g01619460
(B) 80 mm (3.15 inch)

3. Position bosses on the frame. Use shielded metal arc welding with a 5 mm (0.20 inch) fillet weld in order to weld the bosses on the frame. Refer to illustration 2 for group 2 machines. Refer to illustration 3 for group 1 machines.

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Illustration 4	g01619469

4. Install the new retaining plate with a 8T-4956 Bolt and a 8T-4223 Hard Washer to each boss. Apply thread lock to the bolts prior to installation. Torque the bolts to 100 ± 20 N·m (73.76 ± 14.75 lb ft). Refer to illustration 4.

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Illustration 5	g01619470
Group (1) machines after rework.

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Illustration 6	g01619471
Group 2 machine after performing the rework procedure

5. Return the machine to service.