Reference: CAT 1001 SERVICE LETTER

May 27, 2010

ATTENTION: This program must be administered BEFORE this problem occurs. The

decision to apply this program must be made by the Dealer prior to the referenced termination date. Do not perform the work outlined in this Service Letter after the termination date without first contacting your telehandler product support representative.

PROGRAM TERMINATION DATE: May 27, 2011 DESCRIPTION OF ISSUE: This service letters improves the current performance of the AC installation on certain CAT branded Telehandlers.

New parts are available for this installation. APPLICABLE PRODUCTS: This issue affects certain CAT Telehandlers.

Model Affected Serial Numbers EAME

TH336 TDE00104-106,112,115-118,120-123,129,130,133,139,140,143,171-173,176-178, 188-193,204-206,208,211,213,215,217,219,220,222,225-227,229,239,240,251,254.

TH337 TDF00104, 113,119-122,127-129,134-138,140-143,147,148,152-155,168,169, 171,173,175-177,193,215-217,221,223,226,232,234,242,245,246,250,254,

TH406

TBX00101,104,107,114,116,118-121,123,124,126,128-131,133-135,137-139,141-144,147,149-152,154,155,159,160,162,164,165,173,181-185,191-193,200-202,205-209,212,213,215,220,223,225-238,242-250,252,253,258-262,264,265,267-269,271,273-278,280-282,286,288,291-294,296,300,302-317,320-330,332-342,344-352,355,357-376,379-381,383-397,400-402,419.

TH407

TBY00102,103,105-108,111,112,115,118-120,142,145,147,154,160,172-174,177-179,181-184,186-189,192-194,196-200,202-215,217-220,222,225-231,245,246,250,252,253,259-273,275,279,282-289,292-294,296,300-306,308-328,331-353,355,357-363,368-370,372,374,376,377,379-393,395,397,399-401,405,406,408,410-413,415,417-420,422-436, 438-440,442-453,455-460,462,464,468.,472,474-481,484,485,488-491,493,494,496-499,502-504,506-513,516-518,520,521,523,524,527-529,531,535,536,538,539,542-544,546,547,549-555,557,560,564,656,567,569-573,575,576,579-584,586-590,592-605,607-611,613,614,616-626,628-636,638-640,642-644,646-648,650-652,654-672,674,686,687,689-691,695,696,699,701,702,704,705,707,708,710,712,714-716,718-740,742-744,746-748,750,751,754,755,757,761,763,764,766-792,794-803,805,806,808-819, 821-823,825,826,827,830-840,844-855,857-859,860-862,864-867,869,871-873,875-895,903,907,909,923,

PRODUCT SUPPORT PROGRAM TO UPDATE THE AIRCONDITIONING SYSTEM FOR CERTAIN CAT BRANDED TELEHANDLERS.

BEFORE

Page 1 of 14

TH414

TBZ00101,102,104,105,111,116,118,121,122,127,129,135,138,188,189,193,198, 200,202,203,205,210,211,216,217,221,228,230,234,237-239,241-248,251,252,254, 256,258,259,263,265-313,315,320-329,332,334-337,339,376,392,396,398-401,403,409-413, 419,421,423-424,427,428,439-447,449,452,453,456,457,461,462,464-479,486-491,495, 496,499,502-506,509-513,517,519.

TH514 TBW00103-109,112-133,136,137,139,140, PARTS NEEDED: The following part must be ordered to accomplish this update:

Quantity Part Number Description 1 358-9922 Filter, Air 1 358-9912 Seal, HVAC Filter 1 358-9911 Fan, HVAC Blower 1 358-9908 Plate, Blanking 1 358-9910 Duct, Air Hosing 2 358-9909 Grill, Air intake 1 358-9916 Panel HVAC Insulation (a) 1 358-9917 Panel HVAC Insulation (b) 1 358-9918 Panel HVAC Insulation (c) 1 358-9919 Panel HVAC Insulation (d) 1 358-9920 Panel HVAC Insulation (e) 1 358-9921 Panel HVAC Insulation (f ) 1 358-9913 Valve, Restriction 1 121-4342 O-Ring,14.00X1.78, AC restrictor valve 4 358-9914 Screw, Special 2.9X9.5 4 358-9915 Screw, Special 4.8X13 1 315-3849 Hose, Heating 1 358-9886 Bracket AS A/C condenser 1 8T-4224 Washer, Flat 8mm 4 8T-7547 Hex HD Cap screw, 8x30 2 323-7265 Clamp Hose SAE 2 217-6821 Valve, HVAC drainage

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:

Input Field Part Causing Failure CAT1001

Group Number 7320

Warranty Claim Description 56

SIMS Description Code T

The reimbursement terms of this program are as follows:

JLG Dealer Suggested Customer Suggested

Parts % Labor Hrs % Parts % Labor Hrs % Parts % Labor Hrs % 100% 100% 0% 0% 0% 0%

Labor Time: This is an 8.0-hour job. Travel time is up to 2.0 Hours. Mileage is up to 100km.

Page 2 of 14

PROCEDURE: Use the following procedure on the next pages in order to update your machine to the new parts.

- Park the machine on a firm, level surface, level the machine, fully retract the boom, lower the boom, place the travel select lever in the (N) NEUTRAL position, engage the park brake and shut the engine OFF.

- Place a Do Not Operate Tag on both the ignition key-switch and the steering wheel, stating that the machine should not be operated.

Page 3 of 14

Disassembly cover installations

Page 4 of 14

Illustration 1

1. Refer to illustration 1. Remove A/C assembly guard from underneath the cabin as shown. Locate the 4 bolts. Loosen the bolts and remove metal cover (1).

Illustration 2

2. Refer to illustration 2. Remove Front Cabin cover (2) installation.

Illustration 3

3. Refer to Illustration 3. Remove the air intake panel by loosing the 4 screws (3).

1

4

Illustration 4

4. Refer to Illustration 4. Remove the cable from air intake panel and retain the metal clip (4) shown in picture.

2

5

Illustration 5

5. Refer to illustration 5. Remove the floor mat by removing the 2 screws (5) and the holder bar using a 5mm Allen key.

Illustration 6

3

6

6. Refer to illustration 6. Remove cabin floor plate by removing the 4 bolts as indicated (6).

Page 5 of 14

Illustration 7

7. Refer to Illustration 7. Locate cabin air filter (7) and remove it from his location.

Note: Clean this area if required.

Illustration 8

8. Refer to Illustration 8. Loosen front dash panel by removing in total 12 screws.

Note: Some force may be required to use for removing the panel from its position, the panels are flexible to a certain limit.

Illustration 9

9. Refer to illustration 9. Disconnect the 2 connectors from the key switch (8).

10. Remove the panel with the key switch installation still attached.

Removal Air intake plenum

9 7

Illustration 10

11. Refer to illustration 10. Remove the 2 bolts at front of the cabin. (9)

10

Illustration 11

12. Refer to illustration 11. Remove the 4 bolts inside the AC unit (10). These bolts are connecting the plenum to the AC unit.

11

Illustration 12

13. Refer to illustration 12. Pull back the cable (11) and remove the plenum.

8

Removal AC assembly unit.

Page 6 of 14

Illustration 13

Illustration 14

14. Refer to illustration 13 & 14. Remove cab step assembly by removing the 2 bolts at front (11) and ONLY loosing the 2 bolt at both sides (12) for sliding the steps assembly out. Remove as well the P-Clip which holds the routing of the parking cable. (13)

Illustration 15

15. Refer to illustration 15. Remove the P-clip underneath the frame, (14) and remove any cable straps that retain the a/c hoses underneath the cab.

Illustration 16

16. Refer to illustration 16. Disconnect the electrical harness of the a/c assembly.

Illustration 17

17. Refer to illustration 17. Remove the heater valve control cable by releasing the metal clip.

Illustration 18

18. Refer to Illustration 18. Remove the 2 long water drain tubes (15) underneath the AC assembly unit.

11

12

13

15 14

Page 7 of 14

Illustration 19

19. Refer to illustration 19. Support the AC assembly by using a Bottle Jack or similar device.

Illustration 20

20. Refer to illustration 20. Remove the 4 bolts in the cab floor. (16)

Illustration 21

21. Refer to illustration 21. Drop the unit down carefully as shown.

Blower motor replacement

17

Illustration 22

22. Refer to illustration 22. Unscrew 4 screws (17) on both sides of the a/c assembly to allow the motor assembly to be removed from the A/C assembly.

Illustration 23

23. Refer to illustration 23. Replace the existing motor with replacement motor (P/N 358-9911). Refit the motor into the a/c assembly using the 4 screws that were removed in the previous step and re-connect the electrical cable.

Note: Clean the AC assembly unit if required.

16

Thermostat Re-positioning

Illustration 24 Old position.

Page 8 of 14

Illustration 25 New position. 24. Refer to illustration 24 & 25. Remove the foam from

the top of the evaporator matrix then remove the thermostat sensor from the evaporator matrix and re-inserted it to a depth of 80mm in the centre of the evaporator matrix, 90mm from the right hand side of the matrix.

Installation Insulation foam Note: Clean and degrease the areas where the foam has to be installed.

Illustration 26

Illustration 27

25. Refer to illustration 26 & 27. Fit the 6 pieces of self-adhesive insulation foam to the exterior of the a/c assembly.

Note: Some areas of the foam have to be cut to enable the foam to be fitted over water pipes and other connections.

Modification air-intake plenum & Cab panel.

Illustration 28

26. Refer to illustration 28 and attachment I. Make the re-circulation intake hole open by removing the slats (red box) and cut a new hole in the side of the plenum (green box) as shown in the attachment I on page 12. d

f ec

a

b

Page 9 of 14

Illustration 29

27. Refer to illustration 29 and attachment II. Cut two rectangular holes (2 Red boxes) and drill 4 x 1.5mm diameter holes in the cab panel as shown on attachment II.

28. Fit 2 x air grilles (60mm x 120mm) (P/N 358-9909) into the rectangular holes and use 4 screws 2.9x9.5 (P/N 358-9914) to secure them in place.

Re-assembling instruction A/C assembly unit.

29. Refer to illustration 19 .Using a bottle jack re-mount the a/c assembly to the cab floor.

30. Refer to illustration 17 .Re-fit the heater valve control cable. Ensure that the cable travels to the maximum and minimum positions when the control knob in the cab is turned.

31. Refer to illustration 16.Re-connect the electrical connector at the side of the a/c assembly and stow away between the front cab mounts.

32. Refer to illustration 15.Re-fit the P-clip and use cable ties to retain the a/c hoses underneath the cab.

33. Re-fit cab step assembly.

34. Re-fit the modified air intake plenum.

35. Fit the thin piece of self-adhesive foam to the base (interior) (P/N 358-9912) of the a/c assembly (underneath where the air filter is located).

36. Fit replacement air filter. (P/N 358-9922)

Note: Arrows printed on the filter are showing the direction of air flow.

37. Re-fit the cab floor plate.

38. Re-fit the cable to the air intake panel.

18

Illustration 30

39. Refer to illustration 30. Fit new (shorter) (18) water drain tubes (P/N 217-6821) to the underside of the a/c assembly, making sure the grooves on the tubes locate into the steel plate of the a/c assembly.

40. Re-fit a/c assembly guard underneath the cab and floor mat in cab.

Modification Cabin Air vents installation Note: Make sure front and side panels inside the cabin are removed.

Page 10 of 14

Illustration 31

41. Refer to illustration 31. Disconnect the air hose (19) from the round nozzle using a flat-head screw driver.

42. Refer to illustration 31. Remove air hose (20) from the elbow fitting under the upper dashboard panel. Use a flathead screw driver for removing the gear-clamp.

Illustration 32

43. Refer to illustration 32. Remove the elbow fittings from the internal plenum, rotate the left elbow (1) 90 degrees counterclockwise and cover the right (2) hole with blanking plate (P/N 358-9908) using 4x screws (P/N 358-9915).

44. Refer to illustration 32. Mount Hose 3 and 4 to Y-Connection (P/N 358-9910), using existing gear clamps.

45. Mount hose 5 (P/N 315-3846) between the Y-connection and the round nozzle using 2 additional clamps (P/N 323-7265).

Illustration 33

46. Refer to illustration 33. Swap hose 23 with 24.

47. Re-install lower dash front panel and side panel.

48. Re-fit air intake panel to cab and re-fit plastic cover to the front of the cab.

Restrictor installation

49. De-gas the A/C system.

Illustration 34

50. Refer to illustration 34. Locate the A/C compressor in the engine compartment.

51. Loosen and remove the suction line fitting from the A/C compressor (25).

52. Fit restrictor ( P/N 358-9913) in to the suction line replace o-ring with (P/N 121-4342) and re-tighten the fitting.

53. Re-gas A/C system. ( System Capacity 1.1 Kg)

20 19

1

22

2 3

25

23

24

5 4

Replacement A/C compressor bracket

Page 11 of 14

Illustration 35

54. Refer to illustration 35. Remove bottom plate of the engine tray, by removing the bolts from underneath (26).

Illustration 36

55. Refer to illustration 36. Release the belt tension by loosening the bolt (27).

Illustration 37

56. Refer to illustration 37. Remove the V-Belt (28) from its position. Loosen and remove the long bolt (29).

Illustration 38

57. Refer to Illustration 38. Remove the bolt (30) which is attaching the A/C compressor to the concerned bracket.

58. The AC compressor is now loose from the bracket.

Illustration 39 Bracket Old

59. Refer to Illustration 39. Remove the 3 bolts as indicated (31), and remove the bracket.

Illustration 40 Bracket New

26

30

27

31

29

28 32

60. Refer to illustration 40. Install the new bracket (P/N 358-9886) and install additional bolt (32) (P/N 8T-0389) and washer (P/N 8T-4224), apply CAT thread-lock. Torque to 28 Nm.

Illustration 40

61. Refer to illustration 40. Install the compressor to the new bracket.

62. Tension the V-belt to 55± 2 kgF.

63. Refer to illustration 34. Re-install the bottom plate.

64. Check for proper machine functioning, and HVAC operation.

65. Bring the machine back into service. END OF PROCEDURE

Page 12 of 14

Attachment I ( Point 25 page 11)

Modification air-intake plenum.

Page 13 of 14

Attachment II ( Point 26 page 12)

Illustration 2

Page 14 of 14