PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT AXLE RETAINING PIN BOLTED JOINT ON CERTAIN F AND F2 SERIES BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT AXLE RETAINING PIN BOLTED JOINT ON CERTAIN F AND F2 SERIES BACKHOE LOADERS

Usage:

TEBE3853-01

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28Oct2015

(Revised 14Dec2016)

U-579

A-421

D-508

O-506

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT AXLE RETAINING PIN BOLTED JOINT ON CERTAIN F AND F2 SERIES BACKHOE LOADERS
7054 4303 3268		PS53065

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
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 "PS53065" 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 28Oct2015 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Oct2017

PROBLEM

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The existing 8T-4183 Retaining Bolt that retains the 361-5903 Front Axle Mounting Pin can come loose on certain F and F2 Series Backhoe Loaders. If the existing 8T-4183 Bolt comes loose, it can allow the front axle retaining pin to move forward out of the frame bores.

AFFECTED PRODUCT

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Model	Identification Number
415F 2	HWA00150-00392, 50177 PF400150-00156, 158-337
416F	LWT00150-00785
416F 2	HWB00150-00834 LBF01000-01657 LYA00150-00262
416F ST	KSF00150-02254
420F	HST00200-00201 HTG00200 LKH00150-00151, 153-516 LTG00150-01210, 1215-2342
420F 2	HWC00150-01349, 1351-1364 LBS00150-00305 LYB00150-00466, 468-524
420F 2 IT	HWD00150-01076, 1117 LYC00150-00308
420F IT	JWJ00150-03288
420F ST	SKR00150-05380, 6996, 45157
422F 2	LYF00150-00340, 342-663
427F 2	HWK00150-00256
428F	HTB00200 LBH00150-05614, 33976 RAK00150-00610 SJW00150-00425, 430-707
428F 2	HWN00150-00468 LYG00150-00696, 711-1090
430F	LDY00150-00281
430F 2	HWE00150-00325, 327-447 LYD00150-00184
430F 2 IT	HWG00150-00234, 236-346 LYE00150-00186
430F IT	RGS00150-00376, 378-762
430F ST	RDF00150-00332, 334-870
432F	HRH00200-00201 LNR00150-00754, 756-1287 PXR00150-00893 SEJ00150-00445, 447-824, 833-895
432F 2	HWP00150-00731 LYJ00150-00377
434F	FLY00150-00263 LDH00150-00947 MTR00150-00241
444F	FBN00150-00246 HCR00200 JXR00150-00346 LJJ00150-00528

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

NOTE: The bar in this procedure needs to be fabricated locally. Please ensure you have fabricated the bar BEFORE going to the machine to perform this Service Letter Program.

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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, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job
Note: Reasonable costs for fabricating the steel bar needed should be claimed as miscellaneous cost. One bar should be claimed for each machine reworked.

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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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Reminder: Before starting this rework, a dealer fabricated bar will need to be made. Refer to the attached dimensions below for this bar. This will be welded to the machine chassis during the rework.

- Dimensions in Image1.1.1 should be used for 415, 416, 420, 422, 427, 428, 430, 432 models only.

- Dimensions in Image1.1.2 should be used for 434 and 444 models only.

The 434 and 444 models have a modified shape to allow better access when welding.

Fabricate the bar from mild steel.

Note: The 15mm thickness is important. The bar needs to be thicker than the front axle pin flag.

Image1.1.1

Image1.1.2

1. Ensure the machine is on firm, level ground.

2. Raise the loader arms and install the loader safety brace. Ensure the bucket is empty as you will be working below it.

3. Open the front cooling back.

4. Remove the 367-7764 Guard Plate in front of the battery to gain better access to the front axle mounting pin. Refer to Image1.2.1.

Image1.2.1

Note: Ensure the DEF fluid purge is complete (yellow lamp has gone out) on Tier 4 engine machines before disconnecting the battery leads.

5. Disconnect the battery.

6. Remove the battery from the machine and clean any debris from the area.

7. If the 8T-4183 Retaining Bolt is still present, remove the bolt, 7X-0590 Washer, and the 213-6754 Boss from the front axle pin.
Discard the 213-6754 boss. The bolt and washer will be needed again, so keep these safe.

8. Once you have clear access to the pin, the flag needs to be cut with an angle grinder. This is so that the fabricated bar can be installed in to the pin slot.

9. Carefully remove section A shown in Image1.4.1 of the front axle pin flag. The fabricated bar should be a good fit in the pin. Also, carefully grind away the paint 120mm to the right of the flag in order to give a good surface to weld the new bar to.

The bar should fit neatly in the pin as shown in Image1.4.2.

Image1.4.1

Image1.4.2

10. The axle pin should be flush with the frame. If it has come away from the frame (because the bolt was originally loose) push the pin back into place now.

11. Re-install the 8T-4183 Retaining Bolt and the 7X-0590 Washer.

12. The boss that was previously used will not be reused.

13. Once tightened, ensure that the washer is tightened down on to the fabricated bar and there is clearance between the washer and the axle pin flag. Refer to Image1.5.2.

Image1.5.1

Image1.5.2

Prepare the area and the machine for minor welding according to site specific safety practices and Caterpillar general welding guidelines. Refer to the Service Manual if/as necessary.

14. Weld the new fabricated bar to the frame using a 8mm fillet weld. Weld all three sides of the bar.

Note: The bar for the 434/444 is a different shape to allow better access for welding.

Image1.6.1 shows the standard machine weld details.
Image1.6.2 shows the 434 / 444 machine weld details.

Image1.6.1

Image1.6.2

The final repair should look like Image1.7.1.

15. Once the repaired area has cooled, paint the repaired area with a etch primer and then a high gloss yellow top coat.

16. Re-assemble the battery and front guard plate and check the machine for correct operation.