PRODUCT SUPPORT PROGRAM FOR REPLACING THE HYDRAULIC TEE ADAPTER AND HOSE ASSEMBLY ON THE PUMP LINES GROUP ON CERTAIN 424 II BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HYDRAULIC TEE ADAPTER AND HOSE ASSEMBLY ON THE PUMP LINES GROUP ON CERTAIN 424 II BACKHOE LOADERS

Usage:

TEBE0282-01

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22Oct2013

(Revised 14Nov2013)

D-430

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE HYDRAULIC TEE ADAPTER AND HOSE ASSEMBLY ON THE PUMP LINES GROUP ON CERTAIN 424 II BACKHOE LOADERS
5057		PS52547

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52547" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 22Oct2013 Service Letter. Changes have been made to the Affected Product and the Service Claim Allowances.

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TERMINATION DATE

31Oct2014

PROBLEM

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The current 6V-9840 Tee Adaptor, fitted on the pump lines group, leaks during normal operation on certain 424 II Backhoe Loaders.

AFFECTED PRODUCT

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Model	Identification Number
424 II	JRC03520, 3548, 3651-5990, 5997-6352, 6354, 6356-6481, 6483, 6485-6486, 6488-6682, 6685-7177

PARTS NEEDED

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Qty	Part Number	Description
1	3D2824	SEAL-O-RING
4	5K9090	SEAL-O-RING-ORFS
1	6V9840	ADAPTER-TEE
1	7M8485	SEAL-O-RING
1	8T6684	ADAPTER-ELBOW
1	4424975	HOSE AS
1	4424976	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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An alternate design should now be installed on machines that have had tee failures more than two times on the same machine.

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-5000 hrs, 13-24 mo	0.0%	0.0%	0.0%	0.0%	100.0%	100.0%

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NOTE: This is a 4.0-hour job

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PARTS DISPOSITION

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

Rework Procedure

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Refer to the safety measures common for all operations listed below:

1. Park the machine and engage stabilizer.

2. Operate the machine and rest the backhoe bucket on the ground for the support.

3. Operate the loader bucket and lift the machine from the ground.

4. Provide support to the side rail and lock the stabilizer lever.

5. Turn OFF the machine.

6. Operate the hydraulic lever to ensure system hydraulic pressure is released completely.

Refer to the Operation and Maintenance Manual for your machine for additional information on releasing the hydraulic system pressure.

Disassembly Procedure

1. Remove the supply hose connected between the digger control valve (DCV) and the pump side. Refer to Image1.2.1.

Image1.2.1

2. Remove the loader control valve (LCV) hose. Refer to Image1.3.1.

Image1.3.1

3. Remove the 6V-9840 Tee Adapter with the backup tool from the adapter fitted with DCV. Refer to Image1.4.1.

Image1.4.1

4. Remove the adapter from the DCV. Refer to Image1.5.1.

Image1.5.1

5. Remove the return line adapter and hose. Refer to Image1.6.1.

Image1.6.1

Assembly Procedure - Fitting of tee, elbow, and hoses on the DCV side:

1. Ensure that there is an O-ring present on the 6V-9840 Tee Adapter and 8T-6684 Elbow Adapter before starting the assembly. Refer to the table in Image1.7.1 and views in Image1.7.2.

Image1.7.1

Image1.7.2

2. Fit the 8T-6684 Elbow Adapter on the DCV, hand tight. Refer to Image1.8.1.

Image1.8.1

3. Fit the 6V-9840 Tee Adapter on the elbow, hand tight. Refer to Image1.9.1.

Image1.9.1

4. Tighten the 6V-9840 Tee Adapter to a specified torque of 216 +/- 22 N.m. Refer to Image1.10.1.

Image1.10.1

5. Assemble the return line adapter to a specified torque of 300 + 30 N.m and the hose to 216 + 22 N.m. Refer to Image1.11.1.

Image1.11.1

6. Fit the DCV to the pump hose first and then tighten to a specified torque of 216 +/- 22 N.m. First enter the hose with some threads on both the sides and tighten it on the pump side first and tighten it on the DCV side. Refer to Image1.12.1.

Note: Ensure that there is not any twist in the hose after tightening.

Image1.12.1

7. Check the straightness of the pump to the DCV hose. The hose should be straight. If the hose is not straight, adjust the 8T-6684 Elbow Adapter on the DCV and then tighten it to a specified torque of 300 +/- 30 N.m. Refer to Image1.13.1.

Image1.13.1

8. Fit the DCV to LCV hose and tighten to a specified torque of 216 +/- 22 N.m. First assemble the hose with some threads on both the sides and tighten it on the DCV side first and then tighten it on the LCV. Refer to Image1.14.1.

Note: Ensure that there is not any twist in the hose after tightening. The hose elbow orientation should be horizontal to the ground. Ensure that there is no hose contact with other parts after assembly.