PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOOM CHAIN SHACKLES ON CERTAIN TH580B TELEHANDLERS

Usage:

SEBE9038

January 17, 2005
U-21
O-19

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOOM CHAIN SHACKLES ON CERTAIN TH580B TELEHANDLERS
6501, 6404		PI30756

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30756" 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 "PI30756" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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.

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COMPLETION DATE	TERMINATION DATE
July 31, 2005	January 31, 2006

PROBLEM

A material quality problem has been identified on certain TH580B TELEHANDLERS with the retraction chain shackles and pins. If either a shackle or chain retention pin fails, this could prevent the boom from being retracted and may also cause further damage to the internal components of the boom.

AFFECTED PRODUCT

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Model	Identification Number
TH580B	SLH250-278, 280-293, 295, 296, 298-315, 317, 320-334, 338, 339-341, 343-348, 351, 352, 354-356, 384, 405

PARTS NEEDED

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Qty	Part Number	Description
8	3B4605	COTTER
2	2197084	SHACKLE
4	2292807	PIN

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
100%	3.0	0	0	0	0
NOTE: This is a 3.0- hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1- Owner Notification)
(2- Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOOM CHAIN SHACKLES

MODELS INVOLVED - TH580B TELEHANDLERS

Dear Caterpillar Product Owner:

New boom chain retraction shackles and pins need to be installed on the products listed below. The parts may suffer from a failure that could prevent the boom from being retracted and may also cause further damage to the internal components of the boom. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated January 17, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to January 17, 2005 Service Letter

Rework Procedure

Place machine on firm level ground with the boom fully retracted and at 5degrees with the park brake applied.

Illustration 1

Illustration 2

Slacken and remove the fastening nuts from the single extension chain shackle. This is positioned on top of the boom at the front (Illustration 1). Remove the shackle from the locating hole and hang over the boom head (Illustration 2).

Illustration 3

Slacken and remove the fastening nuts from the two retraction chain shackles. These are positioned at the lower front of section 2 (Illustration 3).

Illustration 4

Remove the rear service cover from the machine (Illustration 4).

Illustration 5

Locate the retraction chain pulleys in the rear of the boom (Illustration 5).

Illustration 6

Illustration 7

Remove the pulley pin retaining bolts (A). Remove the pulley pins (B), and then remove the pulleys (C) (Illustration 6 & 7).

Illustration 8

Push the retraction shackles back through the holes towards the center of the boom (Illustration 8).

Illustration 9

Start the machine and telescope the boom sections out by approx 150 mm (Illustration 9).
Turn off machine key switch ignition.

Illustration 10

10) Pull the shackles out of the front of the boom (Illustration 10).

11) Remove the cotter pins and chain pins. Replace the shackles, pins and cotter pins.

Illustration 11

12) To replace the shackles into the locating holes, loop a piece of string through the upper part of the shackle (Illustration 11).

Illustration 12

13) Reposition the shackles behind the anchor point on the boom section (Illustration 12).

Illustration 13

14) Use the loop of string to pull the shackles back through the anchor point. Add the nuts and washers to the shackles to prevent the shackle slipping back through the anchor point. At this point only attach the nuts by 5 mm of thread (Illustration 13).

15) Start the machine and slowly raise the boom to about 45 degrees. Telescope the boom sections in.

16) Lower the boom to 5 degrees. Turn off the machine ignition key switch.

Illustration 14

17) At the rear of the machine, split the top links of the black plastic Igus chain away from the fastened end (Illustration 14).

Illustration 15

18) Remove the two retaining bolts from the chain tray (Illustration 15).

Illustration 16

19) Lift and push the chain tray forward into the boom section to allow access to the retraction chain pins (Illustration 16).

20) Remove the old retraction chain pins and cotter pins. Replace with new pins and cotter pins.

21) Replace the retraction chain pulleys and pulley pins, ensuring that the grease points are facing outwards, and the fastening bolts locate on to the flat of the pin.

22) Replace the extension chain shackle positioned on the front top of the boom, into the anchor. Fit the washer and retaining nut, and tighten by hand.

23) Tighten the retraction chain shackle nuts until there is 10mm of thread showing through the nut.

24) Re-set the chains following the attached procedure.

25) Grease the retraction chain pulleys with the grease specified in the Operation and Maintenance Manual.

26) Replace the rear service cover on the machine.

TH580 Shackle Rework ? Chain Resetting Procedure.

Illustration 17

Measure the gap between section 3 and 4. (Illustration 17)

Illustration 18

Tighten the single extension chain until this gap measures 130mm. (Illustration 18)

NOTE: If this gap is already greater than 130mm, loosen the single extension chain until the nut is on the end of the shackle. Start the machine and raise the boom to 45 degrees or until the boom sections fully retract.

Illustration 19

Tighten the retraction chain shackles to 10 Nm. (Illustration 19)
Tighten the extension chain shackle nut to 80 Nm.
Tighten the retraction chain shackle nuts to 20 Nm, and then increase the torque on both nuts to 30 Nm.
Tighten the extension chain shackle nut to 120 Nm.
Attach all lock nuts and tighten. Extension chain shackle nut 120 Nm, retraction chain shackle nuts 30 Nm.
Finally inspect the orientation of the chain shackles and adjust to ensure that they are not lying twisted and will not foul the underside of the boom sections.