PRODUCT SUPPORT PROGRAM FOR REPLACING THE TELESCOPING CYLINDER ON CERTAIN TH357D TELEHANDLERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TELESCOPING CYLINDER ON CERTAIN TH357D TELEHANDLERS [UEBE1239]

HYDRAULIC SYSTEM

CYLINDER GP

PRODUCT SUPPORT PROGRAM FOR REPLACING THE TELESCOPING CYLINDER ON CERTAIN TH357D TELEHANDLERS

UEBE1239-00

Show/hide table

30Oct2020

U-633

A-521

D-595

O-586

Show/hide table

After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE TELESCOPING CYLINDER ON CERTAIN TH357D TELEHANDLERS
5486		PS54466

Show/hide table

NOTE:	AVSpare’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 AVSpare.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS54466" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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 AVSpare product analyst.

Show/hide table

TERMINATION DATE

31Oct2021

PROBLEM

Show/hide table

The existing telescoping cylinder can leak at the transfer tube on certain TH357D Telehandlers. If the existing telescoping cylinder fails, it can cause a loss of the telescope function and a leak of the machines hydraulic oil.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
TH357D HRC	TD600150-00825
TH357D LRC	TD700150-00173

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	2980466	FITTING-ADAPTER
1	3235622	ELBOW
1	5607647	CYLINDER GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

Show/hide table

New cylinders are easily distinguished from the old by the addition of the welded block on the extremities of the transfer tube. If a failure occurs, replace the existing 560-7647 Cylinder with the improved 560-7647 Cylinder Group as shown in Image1 and 2. Refer to the attached Rework Procedure for removal and installation.

Image1: New Cylinder - The 560-7647 Cylinder Group has three welded support blocks. One at the rear extremity, one in the middle, and one at the front extremity.

Image2: Previous Cylinder - The 560-7647 Cylinder Group has one welded support block in the middle and none at the extremities.

Show/hide table

Image1

Image2

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-7000 hrs, 0-72 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 7.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

Removal and Installation Instructions for TH357D Boom Telescoping Cylinder

INTRODUCTION: This Service Letter details the procedure to remove and install the Boom Telescoping Cylinder on the model referenced in the table below.

INSTALLATION PROCEDURE:

REQUIRED PARTS:
Quantity Part Number Description
1 560-7647 Cylinder Group
1 298-0466 Adapter Fitting
1 323-5622 Elbow

REQUIRED TOOLS:
- Standard Mechanic Tools

PERSONNEL REQUIRED:
- Qualified Equipment Mechanic

INSTALLATION PREPARATIONS:
- Remove any attachment from the machine.
- Park the machine on a firm, level surface.
- Place the transmission in (N) NEUTRAL and engage the parking brake. Shut the engine OFF.
- Place chocks behind the rear wheels.
- Place a 'Do Not Operate Tag' on both the ignition key switch and the steering wheel.
- Open the engine cover. Allow the engine and all system fluids to cool.
- Disconnect the battery negative (-) cable from the battery negative (-) terminal.

IMPORTANT: READ THE ENTIRE PUBLIAVSION BEFORE BEGINNING

NOTE: CERTAIN PARTS HAVE BEEN HIDDEN IN SEVERAL ILLUSTRATIONS FOR CLARITY.

TELECYLINDER REMOVAL:

1. Lower the boom fully so that the pin is in line with dedicated openings in the side frame plates at the rear of the machine. Refer to Image1.4.1.

Image1.4.1

2. Extend the boom to the B section, until front pin (1) is visible from the rod side of the cylinder. Refer to Images1.5.1 and 1.5.2.

3. Remove the circlip for the rear barrel side pin, push the pin out.

NOTE: The cylinder will rest on the lower support block slider.

4. Locate the rear frame cover and remove. Disconnect and remove the hydraulic hitch, if equipped.

5. Have a suitable container and/or oil adsorption cloth to catch hydraulic fluids.

Image1.5.1

Image1.5.2

6. Label, disconnect, and cap tilt hoses (2) and auxiliary hoses (3). Cap all fittings and openings to keep dirt and debris from entering the hydraulic system. Refer to Images1.6.1 and 1.6.2.

Image1.6.1

Image1.6.2

7. Label, disconnect, and cap extend/retract cylinder hoses (4). Refer to Images1.7.1 and 1.7.2.

8. Remove the fittings from the CBV.

9. Keep the holding valve installed to the cylinder.

Image1.7.1

Image1.7.2

10. Loosen and remove the clamps holding the pipe work on the top of the boom. Refer to Images1.8.1 and 1.8.2.

11. Push the pipe work to left and right side to create access to the holding valve.

12. Pull the disconnected hose through the rear opening of the frame and keep them to the left and right side as much as possible.

13. Secure any electrical wiring from getting pinched during the cylinder removal.

Image1.8.1

Image1.8.2

14. Remove the circlips that are securing the full-bore. Refer to Images1.9.1 and 1.9.2.

Image1.9.1

Image1.9.2

CAUTION! To avoid any crushing, please do not position any hands or fingers inside the rear of the frame when the pins of the cylinder are being removed. Position a prybar through the rear of the frame to support the cylinder

15. Place a support or pry bar under the cylinder and remove the pin and spacers. Refer to Image1.10.1.

16. Slowly lower the pry bar to let the cylinder rest on the bottom boom plate.

17. Place a strap through the cylinder pin hole to manually pull out the cylinder.

18. Manually pull the cylinder out through the rear chassis access hole and rotate to clear the attached counterbalance valve.

Image1.10.1

19. When the cylinder is clear of the chassis, use a suitable hoist or lifting device (150 kg) and position a sling around the center balancing point of the cylinder and continue to slide the cylinder out the rear of the chassis. Refer to Image1.11.1.

20. Manipulate the support block over the rear wear pad support plate by rotating the cylinder. The cylinder will almost be out of the boom at this point.

21. Place the cylinder on a pallet or wood blocks.

TELECYLINDER INSTALLATION:

22. Unpack the new cylinder from the wooden crate.

23. Install new a 298-0466 Adapter Fitting and 323-5622 Elbow to the CBV. Tighten to a specified torque of 142 N.m (105 Ft-Lb).

24. Position the sling around the new cylinder, lift and position in toward the rear opening of the frame.

IMPORTANT: CARE AND ATTENTION IS REQUIRED DURING HANDLING OF THE CYLINDER. ANY
DIRECT IMPACT AND FORCE TO TRANSFER TUBE OF THE CYLINDER SHOULD BE AVOIDED.

25. Rotate the front support bracket of the cylinder in order to push it back into the rear frame opening and push the cylinder all the way back into the boom.

26. Clean the original pins and inspect for any dents or damages. Apply a coat of grease inside the cylinder pin bore.

27. Position and line up the bores of the cylinder with the bores at the rear of the boom. Install the pin with the previously removed shims.

28. Secure the pin with the previously removed circlips.

Image1.11.1

29. Reconnect the lines for the cylinder and tighten to a specified torque of 85 N.m (63 Ft-Lb). Refer to Image1.12.1.

30. Reconnect the battery and start the engine.

31. Slowly operate the boom tele-out function until the rod eye of the cylinder is in line with the bores on the fly section.

Note: Any fine tuning can be done by pushing the fly section manually.

32. Reinstall the pin and secure with the previously removed circlips.

33. Reinstall the previously removed clamps (5) holding the pipe work on the top of the boom and tighten to a specified torque of 12 N.m (8.85 Ft-Lb).

34. Reconnect the tilt and auxiliary hose to the pipe work and tighten to a specified torque of 85 N.m (63 Ft-Lb).

35. Place the cable ties on the positions as where removed.

TEST AND RETURN TO SERVICE:

36. Check hydraulic fluid level and add if necessary.

37. Operate the Boom Tele function for 5 cycles at idle to bleed the cylinder.

38. Check for any leaks.

39. Remove container or oil cloths and clean any oil or debris from the main control valve area and surrounding.

40. Reinstall previously removed covers at the rear of the frame.

41. Install any attachment removed from the machine and return machine back to service.

END OF INSTRUCTION