PRODUCT SUPPORT PROGRAM FOR CONVERTING THE 212-1299, 234-9518, 213-6822, 213-6823, 213-6284 AND 197-3944 SWIVEL ACCESS PLATFORMS TO FIXED ACCESS PLATFORMS ON CERTAIN A AND B SERIES TELEHANDLERS

Usage:

SEBE9082

February 26, 2005
U-60
D-51
O-52

Show/hide table

*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR CONVERTING THE 212-1299, 234-9518, 213-6822, 213-6823, 213-6284 AND 197-3944 SWIVEL ACCESS PLATFORMS TO FIXED ACCESS PLATFORMS ON CERTAIN A AND B SERIES TELEHANDLERS
6461		PS41784

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 "PS41784" 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 program is an optional program related to PI10353.

TERMINATION DATE

February 28, 2006

PROBLEM

Recently the 212-1299, 234-9518, 213-6822, 213-6823, 213-6284 and 197-3944 Swivel Access Platforms have been removed from service. This service letter gives details for the replacement of swivel access platforms by converting them to a fixed platform. This is an interim action for all customers who requested the fixed structure to temporarily replace the swivel access platform.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
************************Group 1***************************
Group 1 "A" Series Access Platforms	FGZ075, 080, 081, 083, 085-089, 093, 095, 099-107, 110, 114, 116, 118, 119, 122, 125-136, 138-144, 146-152
************************Group 2***************************
Group 2 "B" Series Access Platforms	SPA201, 203, 204 SJH207-210, 215, 217-221, 225, 228, 230-232, 237, 241, 2188

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
**************Group 1****************
40	7K6536	RIVET-POP
4	8T4223	WASHER-HARD
4	8T4910	BOLT
4	8T8737	PLUG-SEAL
2	1028802	RECEPTACLE K
2	1552270	PLUG KIT-CON
1	1840807	PLATFORM AS.
2	1928663	BLOCK
**************Group 2****************
4	7K6536	RIVET-POP
4	8T7547	BOLT
1	2315382	PLATE
1	2315383	PLATE
1	2327328	BRACKET
1	2335567	PLATFORM AS.
1	2337379	PLATE

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Show/hide table

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
0-6000 ? group 1	100%	5.0	0	0	0	0
0-4000 ? group 2	100%	4.0	0	0	0	0
NOTE: Group 1 is a 5.0?hr job. NOTE: Group 2 is a 4.0-hr job.

PARTS DISPOSITION

Do not handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Retain all remaining parts after carrying out the rework. These parts may be required at a later date when reworking back to a swivel platform.

Attach. (1-Rework Procedure)

Rework Procedure

The object of this procedure is to remove all controls from the existing swivel platform and install them onto the supplied fixed platform frame to provide an alternative/temporary Fixed Access Platform. This will be a temporary fix until there is a final solution for the Swivel Access Platform.

NOTE: Lifting equipment will be required.

Group 1

NOTE: Tools required:- Pop rivet gun, Electric drill and 3mm drill bit. Procedure for removal of components from Swivel Access Platform.

Illustration 1

Disconnect reel electric lead (1) from dummy storage plug.
Unbolt cable guide arm (2), this can be left hanging on the cable.
Disconnect multi pin plug (3) for main wiring harness from reel drum.
Remove reel guard assembly (A).
Remove electric drum reel (4) from support post. This will require lifting equipment to handle safely.
Remove dummy plug assembly 5 from support post.

Illustration 2

Remove the 4 switch covers (6) from switch controls to expose connectors (7).
Record where all wires are attached in each switch control, either by marking each wire or by noting the wire colors. Once the positions of all the wires in each switch control have been noted, remove all of the wires.
Remove the sealed cable clamp fittings (8) at the bottom of each switch control box to allow the wires to pass through.

10) With all wires disconnected carefully feed them through the sealed cable clamp fitting at the bottom of the switch boxes.

11) Pass these wire harnesses through the holes in the rear of the frame, with the rubber grommets (9). (The grommets can be left on the harness.)

12) Disconnect plugs from swivel valve solenoid mounted above swivel motor.

13) Cut any plastic cable ties securing the wiring harness and then remove the harness.

14) Remove all switch boxes from frame.

Illustration 3

15) Remove the nuts that retain the flip chart guides (11) and instruction sheets to the frame and remove them.

16) Use an electric drill to remove the pop rivets securing all the decals to the frame. The swivel decal is not required on this fixed platform, but needs to be retained with the old platform.

17) With all pop rivets removed carefully lift the decals from the frame, you may need to use a blade scrapper to help lift them and be careful not to damage them.

Procedure for installation of components onto fixed frame Platform

Refer to the illustrations above.

Illustration 4

Refit electric drum reel (4) using only the 2 front bolts at this stage. This will require lifting equipment to handle this safely.
Refit the reel guard assembly (A) with the remaining 2 bolts to the inside edge of the reel mounting plate, making sure the bottom edge is behind the control panel plate.

Illustration 5

Refit dummy plug (5) onto support post.
Refit cable guide arm (2) to support plate.
Reconnect reel electric lead (1) onto dummy storage plug.
Refit all switch boxes back onto frame, the only exception here is the swivel control box. Do not fit this to the frame.
Pass the wire harnesses through the holes in the rear of the frame and fit the grommets (9) into the holes in the back plate, (except for the swivel control switch harness).
Carefully feed them up through the sealed cable clamp fittings (8) in the bottom of the switch boxes.
Reconnect the wires in each switch control (7) in the locations recorded when you removed them.

10) With all wires connected make sure they are all positioned securely and then refit the sealed cable clamps (8) and lock into position. 11) Refit all switch covers (6) onto the switch control boxes. 12) At this stage you can refit the wires into the remaining swivel switch control, fit all wires as removed and refit cover. This control box needs to be positioned to the rear of the mounting frame with the excess wiring harness.

13) Reconnect multi pin plug (3) for main wiring harness onto the reel drum.

14) Fit dummy plugs (2 x 155-2270 and 2 x 102-8802 with the 4 x 8T-8737seals) onto the 2 leads that were removed from the swivel solenoid and the 2 left on the solenoids.

Illustration 6

15) Use plastic cable ties to fix the wiring harness to the frame as required and bundle all excess wiring harness together (12) and cable tie to make it secure.

16) Refit the decals onto the frame with pop rivets as shown in layout below.

17) Secure the flip chart guides (11) and instruction sheets to the frame.

18) Finally fit the 2 stop blocks (13) 192-8663 with bolts 8T-4910 to the lower area of the IT frame.

Illustration 7

Illustration 8

19) Finally with all the above installation carried out attach the fixed access platform to the telehandler and carry out a complete operation check for all the functions. For full operating instructions refer to the machines Operation and Maintenance Manual.

Group 2

NOTE: Tools required: - Electronic Technician version 2004B, Pop rivet gun, Electric drill and 3mm drill bit. Procedure for removal of components from Swivel Access Platform.

Illustration 1

Remove the 16 screws (1) that secure the control box cover.

Illustration 2

With the cover removed make a note of the positions of the switches and their wiring or mark them to help when re-installing.
Disconnect the 7 leads as shown above and remove the top cover completely. Remove all the switches from the top cover.

Illustration 3

Disconnect the electric lead (A) to the alarm buzzer and remove the alarm buzzer (B) from inside the control box.
Disconnect the electric lead to the load sensing system (C) and remove the sensor.

NOTE: NACD versions may not have these fitted.

Illustration 4

Illustration 5

Remove the 4 bolts (4) fixing the Electric Control Module (ECM) to the inside of the box compartment. The harness to the ECM (2) does not need to be disconnected.
Remove the cover from the outside of the test port and its fixing to the box, remove the screws (3) securing the test port (D) on the inside of the box.
Cut any plastic cable ties that secure the harness to the inside of the box compartment and from along the rest of the harness route.

Illustration 6

10) Remove the 4 bolts (5) securing the foot pedal to the platform.

11) Lift out the foot pedal assembly and remove the electrical connections.

12) Remove the 3 bolts securing the pedal switch (F) from the base plate (G).

13) Carefully pull the harness through the hole in the main trunk (6) from the foot pedal.

14) All of the harness on the exterior of the platform should now be free and can be fed back up through the hole in the corner of the switch box compartment.

15) Remove the harness complete with the ECM and test port connected.

Illustration 7

16) Remove the 4 bolts (10) securing the plates holding the main control switches.

17) Remove the screws (11) securing these 3 switches to the holding plates.

18) Remove the 2 switches (7), the warning light (8) and the emergency stop switch (9) from the top plate. (See below for details to release emergency stop switch.)

Illustration 8

19) Drill out the 4 pop rivets securing the ID plate and carefully lift from the frame. Procedure for installation of components onto fixed frame Platform

Using the two plates 231-5382 and 231-5383 reinstall switches (D & E) using screws(11).
Install this assembly onto the new top plate 233-7379.
Switch (F) is not required for this fixed platform frame, but will be needed at a later date when reworked back to a swivel platform.
Reinstall the 2 switches (7), the warning light (8) and the emergency stop switch (9) into the plate 233-7379 in the same positions as on the previous platform.
Feed the harness from inside the box through the hole in the corner.
Refit the ECM to the inside of the box compartment using the 4 bolts (4).
Refit the test port (C) with the screws (3) on the inside of the box then refit the cover to the outside of the box.
Reconnect the harness to the switches as previously noted.
Secure harness inside the box with cable ties allowing enough for free movement.

10) You can connect the switch (F) to the harness and place this loose in the control box, also place loose in the control box (if originally fitted) the alarm buzzer (B), the load sensor control (C) and the power filter (E). (These may be required at a later date.)

11) Fit the control box cover (233-7379) with switches onto the new frame.

12) Fit the pedal switch (F) onto the new plate 232-7328.

13) Fit the pedal switch (F) and plate assembly into the frame housing using the new bolts 8T-7547 and original nuts and washers.

14) Feed the harness down the rear of the frame and connect the plug to the foot pedal switch harness (H).

15) Secure the harness (J) to bottom of the frame with cable ties.

Illustration 9

16) Any excess harness needs to be secured to the back of the frame using the fixings (K), making sure you have left enough length to reach the TH connection point.

Illustration 10

Illustration 11

17) Attach all new decals (which are self adhesive) and the ID plate using the 7K-6536 Pop rivets in the positions as shown in Illustration 11.

18) Finally with all the above installation completed you need to attach the Fixed Access Platform onto the Tele-handler (TH), follow the procedure in the O&MM (SEBU7999) Work Tool Installation and Removal.

19) The Access Platform needs to be reconfigured to remove the swivel and load-sensing functions.

NOTE: Not all Access Platforms have the load sensing device fitted but you do need to check on Electronic Technician (ET) that it is not installed. 20) The version of Electronic Technician (ET) required to carry out this procedure should be the latest, which is 2004B. To perform this you need to connect your laptop to the ET connection in the TH cab and follow the instructions below.

Connect ET to the test port in the TH cab.

Illustration 12

Open up your Cat Electronic Technician ? ECM summary and select TH Access Platform ECM. This will then open the configuration menu for the Access Platform.
Expand these groups to show the values for Access platform pivot feature and load sensing installation statuses.

Illustration 13

Double click on the pivot feature and set the value to not installed.
Double click on the load-sensing feature and set the value to not installed.

Illustration 14

Once both the pivot feature and load-sensing feature are set as not installed you can exit the Electronic Technician and disconnect.
Turn off the ignition in the TH and leave off for 60 seconds.
Start the TH and check that all of the Access Platform functions work correctly, refer to the O&MM (SEBU7999) Operator Controls for full details.