PRODUCT SUPPORT PROGRAM FOR REPLACING THE RIDE CONTROL VALVE AND PISTON (ACCUMULATOR) ON CERTAIN TL1055D AND TL1255D TELEHANDLERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE RIDE CONTROL VALVE AND PISTON (ACCUMULATOR) ON CERTAIN TL1055D AND TL1255D TELEHANDLERS

Usage:

TEBE4399-01

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08Mar2016

(Revised 08Mar2016)

U-121

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Before/After Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RIDE CONTROL VALVE AND PISTON (ACCUMULATOR) ON CERTAIN TL1055D AND TL1255D TELEHANDLERS
5004 7750		PS45013

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must 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 "PS45013" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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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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NOTE:	This Revised Service Letter replaces the 08Mar2016 Service Letter. Changes have been made to the travel time allowance in the Service Claim Allowances.

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TERMINATION DATE

31Mar2017

PROBLEM

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The revision of the ride control valve installed on the machines listed may have been ported incorrectly and the accumulator may have been improperly sized on certain TL1055D and TL1255D Telehandlers. To ensure proper operation of the boom ride feature, the control valve and piston (accumulator) must be replaced as a pair.

AFFECTED PRODUCT

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Model	Identification Number
TL1055D	ML500234-00236, 271, 273, 276, 292-293, 317-319, 343, 355, 382, 385, 396, 400
TL1255D HRC	ML700241-00242, 262-263, 272-274, 278, 285, 289-296, 299-300, 302, 308, 311, 317, 337-339, 341-342, 344, 352, 368-396

PARTS NEEDED

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Qty	Part Number	Description
1	4744211	VALVE GP
1	4987903	PISTON (ACCUMULATOR)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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****Parts Stock ****

Inspect all 474-4211 Valve Groups for the correct revision shown in Image1.

- If the 474-4211 Valve Groups are the correct revision, the parts are good, return them to dealer parts stock.

- If the 474-4211 Valve Groups are NOT the correct revision, the parts are bad, remove them from dealer parts stock.

Image1

****Affected Product****

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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%
0-2000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.5-hour job
A maximum of 3.0 hours travel time will be allowed.

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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Rework Procedure

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The correct revision is shown below in Image1.1.1.

Image1.1.1

Park the machine on a firm, level surface, level the machine, and fully retract the boom.

- Properly remove the attachment. Rotate the coupler all the way forward to the mechanical stop, and then rotate coupler up until it just comes off the mechanical stop.
- Command "boom down" and hold, allow the hydraulics to go over relief to de-pressurize the circuit and the piston (accumulator).
- Refer to Images1.2.1 and 1.2.2. Raise the boom to a suitable height to facilitate working around the lift cylinder and at the same time will allow you to properly support the boom head. DO NOT re-engage "boom down" as this will pressurize the circuit.

Image1.2.1

Image1.2.2

- Place the travel select lever in the (N) NEUTRAL position; turn all four wheels all the way to the right and shut the engine OFF.
- Use wheel chocks to prevent the machine from moving.
- Remove the key from the MAIN switch located inside the engine compartment.
- Properly disconnect the battery.
- Place a "Do Not Operate Tag" on both the ignition key-switch and the steering wheel, stating that the machine should not be operated.

Note: Use all applicable safety precautions while working on, around or under any machinery.

Note: Hydraulic oil spillage cannot be avoided while removing the piston (accumulator), hoses, and valve block. Take all precautionary steps to keep the oil contained and minimize spillage as much as possible.

1. Refer to Image1.4.1. Note the orientation of all hoses, adapters, and components. Label for ease of replacement, if desired.

Image1.4.1

2. Disconnect electrical connectors (A).

3. Prepare a means to contain the hydraulic oil that will be lost, slowly loosen hydraulic swivel nut on hose (F), until there is no more pressure.

4. Remove hose (F). Cap and place to side for later reuse.

5. Ensure that the boom head is fully supported before proceeding to the next step, refer back to Images1.2.1 and 1.2.2.

6. Containing the hydraulic oil that will be lost, slowly loosen hydraulic swivel nuts on tube (B), until there is no more pressure.

7. Remove tube (B). Cap and place to the side for later reuse.

8. Remove and retain adapter (G) from piston (accumulator) (D).

9. Loosen band clamps (E). Remove piston (accumulator) (D). The piston (accumulator) (D) will not be reused.

10. Slowly loosen and disconnect hose (I) from valve block (C). Cap and place to the side.

11. Remove and retain all adapters (G) from the valve block (C).

CAUTION!
12. The four cap screws (H) are under extreme hydraulic pressure. Do NOT completely remove them at this time. In a criss - cross pattern, loosen screws (H) one at a time, 1/8th of a turn at a time. Continue this action until you hear an audible "pop" and the boom settles, indicating the hydraulic pressure has been released . At this time valve block (C) can be removed. Block (C) will not be reused. Cover cylinder port block to prevent contamination.

13. Mount new ride control 474-4211 Valve Group (1), with thread locking compound and existing screws (H). Tighten the screws to a specified torque of 28 N.m using an alternating, criss - cross pattern.

14. Reinstall all adapters (G) on the new control valve (1) to the same orientation as noted in Step 1.

15. Reconnect hoses (F), (I), and electrical connectors (A).

16. Reinstall adapter (G) on the new 498-7903 Piston (Accumulator) (2) to the same orientation as noted in Step 1.

17. Loosely mount new piston (accumulator) (2).

18. Reinstall tube (B) that was removed in Step 3.

19. Tighten band clamps (E).

20. Reconnect the battery. Turn on the MAIN switch located inside the engine compartment.

21. Remove the wheel chocks and move the machine to a place where the surrounding area is open and free of obstructions and personnel.

22. Bleed the air from the lift circuit:
- Short cycle the lift cylinder from the full retract position to 3/4 extend to 3/4 retract, two times.
- Fully cycle the lift cylinder from full retract to full extend to full retract, three times. Avoid building maximum pressure at the end of strokes.

23. If needed, top off the hydraulic oil level.

Function Test:

1. Machine at or nearly stationary (boom fully retracted, no load on forks):
- Ensure surrounding area is open and free of obstructions and personnel.
- Raise the boom to approximately 20 degrees.
- Machine should be stationary or moving less than 3 mph.
- Activate the ride switch.
- Lower the boom slightly and immediately release the joystick. There should be NO "Kick" present as the system should be disabled below 3 mph.

2. Machine in motion (boom fully retracted, no load on forks):
- Ensure surrounding area is open and free of obstructions and personnel.
- Raise the boom to approximately 20 degrees.
- Increase the speed of the machine to greater than 3 mph.
- Activate the ride switch.
- Lower the boom slightly and immediately release the joystick. The boom should "Kick" up slightly upon release of the joystick.

24. Remove the "Do Not Operate Tags".

25. Place the machine back in service.