PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE THREADS ON THE BOOM CYLINDER ROD AND REPLACING THE BOOM CYLINDER ROD IF NECESSARY ON CERTAIN 430D AND 430D IT BACKHOE LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE THREADS ON THE BOOM CYLINDER ROD AND REPLACING THE BOOM CYLINDER ROD IF NECESSARY ON CERTAIN 430D AND 430D IT BACKHOE LOADERS

Usage:

SEBE9202

June 1, 2005
U-176

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE THREADS ON THE BOOM CYLINDER ROD AND REPLACING THE BOOM CYLINDER ROD IF NECESSARY ON CERTAIN 430D AND 430D IT BACKHOE LOADERS
5456		PI10385

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10385" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI10385" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The thread on the boom cylinder rod for retaining the piston with a nut may have been over tightened in the manufacturing process on certain 430D and 430D IT Backhoe Loaders. Over tightening will cause threads to be stretched or stripped; leading to the piston nut being pulled off of the rod when the cylinder is operated, causing loss of boom control. The threads on the rods must be inspected to determine whether or not the threads are in good condition.

AFFECTED PRODUCT

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Model	Identification Number
430D	BNK6755, 6756, 6758-6760, 6763, 6764, 6766-6770, 6772, 6774, 6777, 6780, 6781, 6784-6788, 6790-6794, 6797, 6798
430D IT	BML5219, 5233, 5255, 5257

PARTS NEEDED

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Qty	Part Number	Description
1*	2J0564	NUT-SELF LOCK
1*	1844752	ROD AS

*NOTE: These parts are only needed if the threads on the boom cylinder rods are out of specification. Inspect the threads before ordering the parts.

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	3
100%	5	0	0	0	0
NOTE: This is a 3.0-hour job to inspect the threads. NOTE: This is a 5.0-hour job to inspect the threads and replace the boom cylinder rod. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE THREADS ON THE BOOM CYLINDER ROD AND REPLACING THE BOOM CYLINDER ROD IF NECESSARY

MODELS INVOLVED - 430D AND 430D IT BACKHOE LOADERS

Dear Caterpillar Product Owner:

The threads on the boom cylinder rod need to be inspected to check the thread tolerance. If the threads are out of tolerance, a new rod assembly and nut need to be installed on the products listed below. This may cause loss of boom control, which may cause personal injury or death. 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 June 1, 2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to June 1, 2005 Service Letter

Rework Procedure

Thread Micrometer

NOTE: You will need a thread micrometer (1 - 2 inch, 10 - 13 pitch) in order to complete this inspection.

Remove the 184-4752 Rod from the 205-8655 Boom Cylinder.
Remove nut and piston from the rod; then clean oil off the threads.

Measuring and Inspecting Locations

Visually inspect that the threads are in good form; peaks and valleys are evenly spaced and no evidence of thread damage.
Place a 1 - 2 inch thread micrometer 4 threads in from the end of the rod. Measure and record the pitch diameter of the thread.
Move the micrometer to the 11^th thread from end of the rod. This should be the center of the thread length. Measure and record the pitch diameter of the thread at this point.
Place the micrometer on the 4th thread starting at the chromed end of the rod. Measure and record the pitch diameter of the thread.
The thread pitch measurements must conform to the following specification:

The pitch diameter tolerance range for a 2-12-2A thread is 1.938 to 1.944 inches.
A pitch diameter that measures less than 1.938 inches is not acceptable.
A variation of more than 0.002 inches between the three readings is not acceptable.

Replace the rod assembly with a new rod assembly and a new nut if threads do not conform. Reuse the rod assembly and nut if the threads do conform to specifications.
Assemble the piston onto the rod.

10) Lubricate the threads, assemble the nut onto the rod, and tighten the nut to 3200 ± 200 N-m (2360 ± 150 lb-ft). 11) Assemble the rod assembly into the cylinder. Seals can be reused if they have not been damaged.