PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RIGHT SIDE LADDER AND REPLACING THE HANDRAIL CLAMPS ON CERTAIN PM620 AND PM622 COLD PLANERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RIGHT SIDE LADDER AND REPLACING THE HANDRAIL CLAMPS ON CERTAIN PM620 AND PM622 COLD PLANERS

Usage:

TEBE4865-00

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05Jul2016

U-347

O-306

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RIGHT SIDE LADDER AND REPLACING THE HANDRAIL CLAMPS ON CERTAIN PM620 AND PM622 COLD PLANERS
7256 7254		PI11080

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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 as soon as possible. When reporting the repair, use "PI11080" 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 "PI11080" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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PROBLEM

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The right side ladder needs to be reworked and the handrail clamps need to be replaced on certain PM620 and 622 Cold Planers. The existing ladder may swing out when the operator is trying to close the gate while standing on the ladder or while ingressing or egressing the base of the ladder and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
PM600	JFC00101-00107
PM620 HRC	JB900103-00109

PARTS NEEDED

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Qty	Part Number	Description
1	8C4428	SOCKET-LATCH
1	8T4138	BOLT-HEX HEAD
1	8T4971	BOLT
1	9R8538	PLUNGER-LATCH
1	9X2038	WASHER-HARD
2	9X8256	WASHER
2	3445673	NUT-HEX
1	PART_KIT	SHIPPED DIRECT TO DEALER (See Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Rework the ladder and replace the handrail clamps per the attached Rework Procedure.

Note: In addition to the listed required parts, a kit of parts will be sent to the service letter coordinators. If this kit is not received, please contact DSN and ask for Tier 2 support regarding this service letter.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 6.0-hour job

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PARTS DISPOSITION

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

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE RIGHT SIDE LADDER AND REPLACING THE HANDRAIL CLAMPS ON CERTAIN PM620 AND PM622 COLD PLANERS

MODELS INVOLVED - PM620 and PM622 Cold Planers

Dear Cat Product Owner:

The right side ladder needs to be reworked and the handrail clamps need to be replaced on the products listed below. The existing ladder may swing out when the operator is trying to close the gate while standing on the ladder or while ingressing or egressing the base of the ladder and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 05Jul2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 05Jul2016 Service Letter

Rework Procedure

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This procedure provides the instructions to rework the right side ladder and replace the handrail clamps on certain PM620 and PM622 Cold Planers.

The supplied parts kit will include the following:
ITEM 1: 204-0543 BAR QTY:2
ITEM 2: 478-7425 PLATE QTY:1
ITEM 3: 508-9047 PLATE QTY:2
ITEM 4: 508-9048 PLATE QTY:2
ITEM 5: 478-7435 PLATE QTY:1
ITEM 6: 512-8130 CLAMP QTY:12 (24 clamp halves total)

Prepare the Machine for Rework

Park the machine on a hard level surface.

Image1.1.1

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls. Attach the warning tag before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer.

Image1.2.1

Secure the right side gate (A) in the closed position or fold the right side hand rail system inboard.

Remove the 478-7436 (B) and 478-7139(C) Ladders from the machine.

Rework the 478-7139 Ladder (C), referring to Image 1.4.1 through Image 1.4.4 for details.

* Weld the 204-0543 Stop Bar (1) to the existing 478-7139 Ladder (C).

* Weld the 478-7425 Plate (2) to on the left side of the existing 478-7139 Ladder. (It will be a mirror image of the existing 478-7425 Plate. The back of the plate is on the center line of the tube.)

* Elongate the existing ladder pivot holes downwards, converting them into slots(D). This can be done by drilling a 11.5mm hole 16mm below the center of the existing hole and then removing the material between the two holes. The total length of the slot should be 27.5mm. The width is 11.5mm.

* Prepare and paint the newly added components and weld affected areas black.

* Install the 9R-8538 Plunger onto the new plate (2) using the 8T-4971 Bolt, 9X-8256 Washer and 344-5673 Nut.

Image1.4.1

Image1.4.2

Image1.4.3

Image1.4.4

Rework the 478-7436 Ladder (B), referring to Image 1.5.1 through Image 1.5.3 for details.

* Weld 508-9047 Plate (3) and 508-9048 Plate (4) to the existing 478-7436 Ladder (B).

* Weld 478-7435 Plate (5) to left side of the existing 478-7436 Ladder (B). (It will be a mirror image of the existing 478-7435 Plate. The center of the plate thickness is on the center line of the tube.)

* Prepare and paint the newly added components and weld affected areas black.

* Install the 8C-4428 Socket on to the new plate (5) using the 8T-4138 Bolt, 9X-2038 Washer, 9X-8256 Washer and 344-5673 Nut.

Image1.5.1

Image1.5.2

Image1.5.3

Reassemble the ladders to the machine. Check that the ladder lock retains the ladder (C) in the DOWN position and the that new plunger and socket mate up when the ladder (C) is in the UP position.

Replace the 7R-7941 Clamps in the 374-1343 Handrail Gp with the supplied 512-8130 Clamps (10 places.) Refer to Image 1.6.1.

Replace the 7R-7941 Clamps in the 374-1344 Ladder Gp with the supplied 512-8130 Clamps (2 places.) Refer to Image 1.6.2