244831 Volvo.Penta Piston

April 18, 2001
(Revised August 2001)
U-93
beforeor
after failure PRODUCT SUPPORT PROGRAM FOR UPDATING THEENGINE AND RADIATOR MOUNTS TO PROVIDE LONGER SERVICE LIFE ON CERTAIN 539KNUCKLEBOOM LOADERS
1353 PS40564
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS40564"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe April 18, 2001 (Revised May 2001) Service Letter. Changes have beenmade to the Affected Product and the Service Claim Allowances.TERMINATION DATE
April 30, 2003PROBLEM
The engine and radiator mounting should be updatedto provide longer service life on certain 539 Knuckleboom Loaders. Thebolts in the engine mounts may loosen and/or the radiator support may crack.These mounts need to be replaced.AFFECTED PRODUCT
539 1PZ103-125, 127-130, 139-142PARTS NEEDED
8 - 8T4223 Washer - Plate
8 - 8T4956 Bolt
2 - Plate ? Mounting (fabricated)
2 - Plate ? Spacer (fabricated) The plates should be made from standardstructural steel per Illustrations 1 and 2.ACTION REQUIRED
See the attached rework procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-4000/ 0-24 mo 100% 18 0 0 0 0
4001-6000 /25-36 mo 33 1/3% 9 0 0 50% 9
This is a 18-hour job. U.S. and Canadian Dealers Only - Dealersmay enter a Type 2 SIMS report.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
The engine and radiator should be removed to performparts 1 and 2 of this service letter. Refer to RENR3077, "Disassembly andAssembly ? 539 Knuckleboom Loader Engine Supplement", for instructionson removal and installation of these components.Part 1: Update 8L4495 Radiator Shell, partof 1712885 Radiator Gp
Locate .5" mounting plate .5" setback from frontedge of shell and .5" extended past bottom of shell as shown in Illustration3. Locate .120" plate In gap created by formed edge on rear engine sideof shell and flush with top and bottom of mounting plate.
Drill out existing holes (quantity 4) in eachside of the radiator shell (near bottom) to 0.5" diameter to provide clearancefor the new 12mm mounting bolts. Also drill the corresponding holes inboth 1003841 Bracket Assembly (RH) and 1003842 Bracket Assembly (LH) to0.5" diameter in order to provide clearance holes for 12mm mounting bolts.These brackets were previously used to mount the shell.
Align holes in the shell, spacer plate, and reinforcementplate. Secure plates with clamps or bolts.
Weld spacer plate to reinforcement plate top andbottom of plate enough to keep it in position and ease assembly. Use 3mm fillet weld. Tack and weld completely around perimeter of reinforcementplate to shell joint with 3mm fillet weld. Break into short and spacedpasses to avoid distortion of shell.
Place shell and radiator assembly back in machinepositioned as it was when previously installed. Attach using 8T4956 Bolts(M12 X 1.75) and 8T4223 Washers installed from the inside of the bracketsout.
Part 2: Update to Engine MountsThis procedure consists of adding weld to theexisting bolted joints. See Illustration 4 for location and size of weldsto be added to the engine mounts.
Illustration 1: Plate ? Spacer