PRODUCT SUPPORT PROGRAM FOR UPDATING THE GRAPPLE TONG CYLINDER PIN TO PREVENT PREMATURE FAILURES ON CERTAIN 535B AND 545 WHEEL SKIDDERS

Usage:

SEBE7833-02

November 16, 2001
(Revised December 2001)
U-315
AU-209
S-160
H-118
O-240

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE GRAPPLE TONG CYLINDER PIN TO PREVENT PREMATURE FAILURES ON CERTAIN 535B AND 545 WHEEL SKIDDERS
5555-ZY		PS40792

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS40792" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, 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 November 16, 2001 (Revised November 2001) Service Letter. Changes have been made to the Service Claim Allowances.

TERMINATION DATE

November 30, 2003

PROBLEM

The grapple tong cylinder pin should be updated to prevent premature failures on certain 535B and 545 Wheel Skidders. The new pin (see Item 27 on Illustration 1) eliminates the cross-drilled grease hole, reducing the stress concentration in the pin. Grease will now be applied through a fitting located in the cylinder rod eye. Later production grapples have a larger pin.

AFFECTED PRODUCT

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Model	Identification Number
535B	AAE401-462, 500-503
545	2FZ235, 239-241, 245, 250, 251, 253-262, 264, 265, 268, 269, 272, 274, 276, 278-280, 284, 285, 288, 290, 292-295, 300, 301, 303-305, 311-313, 322, 323, 325, 327, 330, 334, 354, 356

NOTE: Caterpillar has made an effort to match the affected grapple head arrangements and serial numbers to the corresponding machine serial numbers, however it is possible that some serial numbers have been missed or that some have been included that should not have been. Use the following criteria if you are not sure if the grapple in question should have the program performed:

535B (AAE401 and Up) equipped with a 1699590 Bunching Head, all grapple head serial numbers through SNFP25624.

545 (2FZ00235 and Up) equipped with a 1510872 Bunching Head, all grapple head serial numbers SNFP22735 through 24835.

PARTS NEEDED

2 - 3B8489 Fitting - Hydraulic
2 - 2039208 Pin Group
2 - 2039209 Bushing

ACTION REQUIRED

See the attached Rework Procedure.

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
0-5000/ 0-30 months	100%	5	0	0	0	0
5001-6000/ 31-36 months	33 1/3%	2.5	0	0	50%	2.5
NOTE: This is a 5?hour job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Illustration 1

Caterpillar has made an effort to match the affected grapple head arrangements and serial numbers to the corresponding machine serial numbers, however it is possible that some serial numbers have been missed or that some have been included that should not have been. Use the following criteria if you are not sure if the grapple in question should have the program performed:

535B (AAE401 and Up) equipped with a 1699590 Bunching Head, all grapple head serial numbers through SNFP25624.

545 (2FZ00235 and Up) equipped with a 1510872 Bunching Head, all grapple head serial numbers SNFP22735 through 24835.

535B Reference: RENR4344 ? Disassembly and Assembly of 535B Wheel Skidder Machine Systems, Grapple Tong Cylinder Remove and Install.

545 Reference: RENR3054 ? Disassembly and Assembly of 545 Wheel Skidder Machine Systems, Grapple Tong Cylinder Remove and Install.

Remove the grapple tong cylinders. Remove the bushings from the rod end of each cylinder and discard.

Illustration 2
Dimensions for collar

Fabricate a collar according to the dimensions in Illustration 2.

Illustration 3

Drill hole through the eye of the cylinder rod and tap for grease fitting per Illustration 3.
Weld the collar as shown in Illustration 3 and install the 3B8489 Grease Fitting. Press frozen 2039209 Bushing, into the cylinder rod eye. Be sure to align the grease path with the hole that has been drilled. Apply grease to the fitting to ensure flow into the I.D. of the bushing.
Repeat for the other cylinder. Install the cylinders in the grapple using new solid 2039208 Pins. Grease the joints and test operation.