SERVICE LETTER

Reference: #C107C1
August 1, 2007

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE

RETRACTION BOOM SHACKLES AND IMPLEMENTING A
SAFETY REVISED BOOM CHAIN ADJUSTMENT PROCEDURE ON
CERTAIN CATERPILLAR MODEL TH580B TELEHANDLERS

ATTENTION: This notice is being issued to advise you of the requirement to update certain
Caterpillar (“CAT”) Telehandlers that were manufactured by JLG Industries,
Inc. (“JLG”). This program must be completed as soon as possible on all
affected machines.

PROBLEM:
Reports indicate that the boom chains are being incorrectly adjusted during boom servicing.
Incorrect adjustment of the chains may cause premature failure of the chain shackles. The
failure of both chain shackles will result in the inability to retract the boom or uncontrolled
restraint of the outer boom sections when the boom angle is below horizontal. This could result
in a crushing hazard or loss of load.

AFFECTED PRODUCTS:
This issue affects certain CAT Telehandlers Model TH580B manufactured by JLG. The affected
machines have the following serial numbers:

Model Affected Serial Numbers

TBJ00100 to TBJ00230,
TBJ00232 to TBJ00236,
TBJ00238 to TBJ00241,
TBJ00243 to TBJ00245,
TH580B TBJ00247 to TBJ00249,
TBJ00252 to TBJ00263,
TBJ00268 to TBJ00273,
TBJ00275,
TBJ00277 to TBJ00279

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PARTS NEEDED:
The following parts must be ordered to accomplish this update:

Quantity Description Part Number

4 Cotter 3B4605
2 Pin 3072248
2 Shackle 3072247
Operation and Reference the enclosed
1
Maintenance Manual “Manual Order Form”

ACTION REQUIRED:
Parts Stock
Remove all original shackles (#2197084) from dealer parts stock.
Affected Machines:
- Perform the enclosed Chain Shackle Replacement Procedure:
- Replace the original boom retract chain shackles with new chain shackles designed to
reduce the risk of incorrect adjustment.
- Adjust the chain shackles using the new adjustment procedure.
- Order a new Operation and Maintenance Manual using the enclosed Manual Order Form.
- Remove and discard the original Operation and Maintenance Manual. Install the new
Operation and Maintenance Manual on the machine prior to returning it to service.

SERVICE CLAIM ALLOWANCES:

To receive reimbursement, file a service claim through the normal CAT service claims process.
When filing this claim through the CAT system, please use the following codes in the
appropriate input fields:
- Part Causing Failure: C107C1
- Group Number: 771J
- Problem Description Code: AA
The reimbursement terms of this program are as follows:
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs % Parts % Labor Hrs % Parts % Labor Hrs %
100% 100% 0% 0% 0% 0%
NOTE: This is a 3.0 hour job

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

CONTACTS:
A copy of this Service Letter will be available on the JLG-CAT Alliance website. If you have any
questions or need further information, please contact the JLG Product Safety and Reliability
Department by:
Email: [email protected]
Telephone: +1 717 485 6591

Enclosures:
Chain Shackle Replacement Procedure
Manual Order Form

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PROCEDURE: Chain Shackle Replacement, Service Letter #C107C1
MODELS: CAT Telescopic Material Handlers Model TH580B

Parts/Material Required:
- Cotter, #3B4605, quantity 4
- Pin, #3072248, quantity 2
- Shackle, #3072247, quantity 2
- Updated Operation and Maintenance Manual, quantity 1

Operation and Part Operation and Part

Maintenance Manual Number Maintenance Manual Number
English 31200245 Italian 31200342
French 31200295 Danish 31200348
Turkish 31200315 Polish 31200351
Portuguese 31200323 Dutch 31200356
Spanish 31200322 Greek 31200391
German 31200339 Bulgarian 31200390
Czech 31200398

CAUTION: USE ALL APPLICABLE SAFETY PRECAUTIONS WHILE WORKING

ON, UNDER OR AROUND ANY MACHINERY.

Procedure:
1. Position machine on a firm and level surface. Fully retract and raise the boom to
approximately 5 degrees above horizontal. Turn off engine and apply park brake.

2. Locate and remove the locking nut (outer nut) from the single extension chain
shackle. Reference Figure 1. Loosen, but do not remove the adjusting nut from
the same shackle. Leave adjusting nut engaged on the last two threads of the
shackle.

Figure 1

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3. Loosen and remove the fastening nuts from the two boom retract chain shackles
located on the underside of the second boom section toward the front of the
machine. Reference Figure 2.

Figure 2
4. Remove the service cover from the rear of the machine to access the boom
retract chain pulleys.

5. Locate the retract chain pulleys in the rear of the boom. Reference Figure 3.

Figure 3

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6. Remove the pulley pin retaining bolts (A) and the pulley pins (B). Reference
Figure 4.

Figure 4

7. Remove the pulleys (C). Reference Figure 5.

Figure 5

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8. Push the threaded end of the shackles through the holes toward the center of the
boom. Reference Figure 6.

Figure 6

9. Start the machine. Telescope the boom out by approximately 150 mm and shut
down the machine. Reference Figure 7.

Figure 7

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10. Pull both shackles out from the front of the boom. Reference Figure 8.

Figure 8

11. Remove the cotters and chain attachment pins from both shackles and remove
the shackles.

12. Install the new shackles (#3072247), chain attachment pins (#3072248), and
cotters (#3B4605).

13. Replace the shackles through the locating holes. Place a string through the
shackle between the chain attachment pin and the end of the shackle. Use the
string to pull the shackle back through the locating hole. Reference Figures 9
and 10.

Figure 9

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 Figure 10

14. Once the shackles are through the positioning holes, add the washers and nuts
to prevent the shackles from slipping back through the anchor point. Only attach
the nuts by 5 mm of thread.

15. Start the machine and slowly raise the boom to approximately 45 degrees. Then
fully telescope the boom inward.

16. Lower the boom to 5 degrees above horizontal and shut down the machine.

17. Replace the retract chain pulleys and pulley pins at the rear of the boom. Ensure
that the grease fittings are facing outward, and the fastening bolts are located on
the flat part of the pin.

18. Grease the retract chain pulleys with the type and amount of grease specified in
the Operation and Maintenance Manual for the machine.

19. Before beginning the boom chain adjustment procedure, ensure the machine is
on firm, level ground with the park brake applied.

20. Lower the stabilizer legs (outriggers) and fully extend the boom. If necessary,
raise it to an appropriate height to allow access to the retraction chain shackles
on the underside of the boom.

21. Place a suitable stand underneath the boom for additional support, and turn off
the engine.

22. Remove the locknuts from all seven (7) of the boom chain shackles.

23. Loosen the adjustment nuts on all chain shackles until the end of the shackle is
flush with the end of the nut. Ensure no threads are protruding from any of the
adjustment nuts.

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24. Start the engine and retract the boom 200 mm (7.87 in). Once the boom is
retracted, turn off the engine.

25. Adjust the retraction chains underneath the first boom section such that 30 mm
(1.18 in) of thread is exposed between the outer face of the nut and the end of
the thread on the shackle. Reference Figure 11.

Figure 11

IMPORTANT! ENSURE THE CHAIN SHACKLES ARE LYING STRAIGHT

WITHIN THE BOX SECTION OF THE BOOM AND ARE NOT
TWISTED.

26. Adjust the retraction chain shackles underneath of the second boom section until
15 mm (0.59 in) of thread is exposed between the outer face of the nut and the
end of the thread on the shackle. Reference Figure 12.

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 Figure 12

IMPORTANT! ENSURE THE CHAIN SHACKLES ARE LYING STRAIGHT

WITHIN THE BOX SECTION OF THE BOOM AND ARE NOT
TWISTED.

Page 8 of 11
27. Tighten the extension chain nuts on the first section evenly, regularly switching
from left to right, until the clearance between each chain and the boom section is
90 mm (3.54 in). Reference Figures 13 and 14.

Figure 13

90mm

Figure 14

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28. Tighten the extension chain on the second section until the clearance between
the chain and the boom section is 90 mm (3.54 in). Reference Figures 14 and
15.

Figure 15

29. Remove the stand and all tools from the working area and start the machine.

30. Fully retract the boom and then fully extend the boom. Retract the boom again,
only by 200 mm (7.87 in).

31. Turn off the machine, and replace the stand beneath the boom.

32. Check the clearance between all extension chains and the boom sections. For
each extension chain, the proper adjustment measurement is 90 mm (3.54 in).
Reference Figure 14.

33. If the adjustment is less than 90 mm (3.54 in), tighten the appropriate extension
chain shackles to achieve the required adjustment (90 mm). Reference Figures
13 and 15.

34. Fully retract the boom and then fully extend the boom.

35. With the boom at full extension, verify the clearance between the chain and the
boom is, at minimum, 90 mm (3.54 in).

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36. If this is not the case, repeat the adjustment procedure, until proper adjustment in
each chain is consistently achieved.

37. Add and tighten the lock nuts on all chain shackles.

IMPORTANT! DO NOT USE ANY THREAD LOCK ON THE SHACKLE LOCK

NUTS. SHACKLE THREADS MUST BE CLEAN AND DRY.

38. Before the machine is returned to service, ensure all shackles are lying straight
within the box section if the boom and are not twisted.

39. Reinstall the rear boom cover.

40. Discard the original Operation and Maintenance Manual. Install an updated
Operation and Maintenance Manual in the appropriate location on the machine.

41. Confirm proper operation of all boom functions.

42. The machine may be returned to service once proper operation is confirmed.

Should any further discrepancies be discovered during the accomplishment of this

procedure, please contact JLG for further evaluation.

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 MANUAL ORDER FORM
Reference #C107C1

Machine Serial Number(s):

Specify Operation and Maintenance Manual (Limit one per serial number):

Languag
(3) Language Part Number Qty. (3) e
Part Number Qty.

English 31200245 Italian 31200342

French 31200295 Danish 31200348
Turkish 31200315 Polish 31200351
Portuguese 31200323 Dutch 31200356
Spanish 31200322 Greek 31200391
German 31200339 Bulgarian 31200390
Czech 31200398

Fax, email, or mail the completed form to:

JLG Manufacturing Europe BVBA
Caterpillar Alliance Group
Industrieterrein Oude Bunders 1034
Breitwaterstraat 12A
B-3630 Maasmechelen
Belgium
Fax: +32 (0) 89 77 85 37
Email: [email protected]

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Company:

Address:

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