PIN 5V4999 - Caterpillar

Image2.3.1
Group 2 and 3 - Rework Procedure:
1. Have the Dealer TC submit a DSN - Product Health service request with reference to this Service Letter number (TEBE5087) and lift arm serial number in the description field. Also, include the request for DXF drawings for TOOL1, TOOL2 and BLOCK in the description field.
Note: DXF files are available for machining purposes.
2. Fabricate TOOL1 and TOOL2. Refer to Image2.4.1.
Note: Drawings and DXF files available through the DSN, per Step 1.
Image2.4.1
3. Fabricate two BLOCKS. Refer to Image2.5.1 for material specifications and requirements.
Note: Drawings and DXF files available through DSN, per Step 1.
Image2.5.1
4. Remove the work tool from the machine. Refer to SEBU9222, Operation and Maintenance Manual, Operation Section, "Work Tool Operation".
5. Position the machine on firm level ground, engage the park brake. Isolate the machine and install the steering frame lock, refer to SEBU9222, Operation and Maintenance Manual.
6. Remove the vertical pin coupler from machine. Refer to UENR6753, Disassembly and Assembly, "Quick Coupler Remove and Install".
7. Use blocks/supports to support the lift arm in readiness for removal of blocks. Install a 237-5562 Pin into lift arm bore. Refer to Image2.6.1.
Image2.6.1
8. Grind off the welds and remove the blocks from both sides of the lift arm. Refer to Image2.7.1.
Note: Use suitable covering over the front frame and cab to protect the machine from grinding dust contamination, and use suitable PPE when performing this operation.
Image2.7.1
9. Prepare the lift arm surface for welding the fabricated BLOCKS into place.
10. Use TOOL1 and TOOL2 to locate the BLOCK, and tack weld in place. Refer to Image2.8.1 and 2.8.2.
Image2.8.1
Image2.8.2
11. Complete a 6mm bevel weld, then add an 8mm fillet along the top edges of the BLOCK. Refer to Image2.9.1 for more detail.
Note: The fillet weld should be no larger than 10mm. Refer to REHS1841, General Welding Procedures, and SEBD0512, Caterpillar Service Welding Guide.
Image2.9.1
12. Raise the loader arm in order to gain access to the underside of the BLOCK and support using blocks/stands.
13. Complete a 6mm bevel weld, then add an 8mm fillet along the bottom edges of the BLOCK. Refer to Image2.10.1 for more detail.
Note: Fillet weld should be no larger than 10mm. Refer to REHS1841, General Welding Procedures, and SEBD0512, Caterpillar Service Welding Guide.
Image2.10.1
14. Remove the 237-5562 Pin into lift arm bore.
15. Clean and dress weld area and lift arm surface in readiness for paint.
16. Paint the affected area using the following procedure:
Aerosol Touch-Up Application
PRIMER AND TOPCOAT
a) Shake aerosol can for a minimum of 3 minutes to ensure proper agitation. Spray practice area to check nozzle and fluid delivery system. Adjust spray pattern on nozzle to improve coverage. (Turn horizontally or vertically)
b) Sand topcoat and primer to bare metal with 120-180 grit sand paper.
c) Apply Henkel Wipe M-NT1455-W, allow to dry 15 minutes.
d) Apply primer in 3-4 passes with a crossing pattern over repair area and allow to dry for 30 minutes before applying topcoat.
e) To save a partially used can of primer for later use: immediately after application, and before storage, turn can upside down and