BRUSH-POLYPROPYLENE 3028211 - Caterpillar

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.
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 ROTARY POSITION SENSOR ON THE LEFT PEDAL ON CERTAIN 815F, AND 825H SOIL COMPACTORS, 816F, 826H, AND 836H LANDFILL COMPACTORS, 824H, 834H, AND 844H WHEEL DOZERS, 988H, AND 990H WHEEL LOADERS
MODELS INVOLVED - 815F, 816F, 824H, 825H, 826H, 834H, 836H, 844H, 988H AND 990H
Dear Caterpillar Product Owner:
The 2661478/">266-1478 Rotary Position Sensor for the left pedal needs to be replaced. The existing sensor can cause the machine to shift gears excessively or operate intermittently. 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 08Mar2012 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 08Mar2012 Service Letter
Rework Procedure
Note: Retain and reuse all removed hardware.
Removing the 2661478/">266-1478 Position Sensor change level 02
1. Disconnect the brake lamp switch and rotary sensor DT connectors.
Image1.1.1
2. Remove the M8 bolts holding down the left pedal and remove the pedal for easier access to the cover.
3. Remove the six cover screws. If there is a rubber seal, ensure that it does not fall out or get damaged. The seal will be reused.
Image1.3.1
4. Remove the two rotary position sensor mounting screws and remove the rotary position sensor.
Image1.4.1
Installing the new 2661478/">266-1478 Position Sensor change level 03
Note: replacement of the new sensor depends on the pedal type being reworked. If the machine is an 844H or 990H, proceed to Step 3.
1. (815F, 816F, 824H, 825H, 826H, 834H, and 988H only) Loosen but do not remove the treadle plate set screw about two full turns. This will allow the pedal shaft to align with the sensor slot.
Image1.5.1
2. Using pliers or an 8mm socket, turn the shaft slightly clockwise approximately 10 degrees. This will allow shaft alignment to the sensor.
Image1.6.1
3. Carefully place the new 2661478/">266-1478 Position Sensor change level 03 into the pedal aligning the shaft to the sensor slot.
Image1.7.1
4. Reinstall the sensor screws, applying 242 Loctite and tightening to 2.4 Nm +/- 0.4 Nm.
5. Reinstall the cover plate. If there was a rubber seal, ensure that the existing rubber seal is put back in place. Reinstall the cover plate screws, applying 242 Loctite and tightening to 2.4 Nm +/- 0.4 Nm.
6. (815F, 816F, 824H, 825H, 826H, 834H, and 988H only) Retighten the treadle plate set screw to 9.6 Nm +/- 1.2 Nm.
Image1.10.1
7. Reinstall the pedal aligning with the brake shaft and bolt holes in the floor of the cab.
Image1.11.1
8. Reinstall the three M8 bolts and tighten to 28 Nm +/- 7 Nm.
9. Reconnect the brake lamp and rotary sensor connector.
10. Calibrate the left pedal in