PRODUCT SUPPORT PROGRAM FOR REWORKING THE SERVICE BRAKE ON CERTAIN 416F2 AND 420F2 BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE SERVICE BRAKE ON CERTAIN 416F2 AND 420F2 BACKHOE LOADERS

Usage:

TEBE6737-03

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13Feb2018

(Revised 21Mar2019)

U-85

A-68

D-79

O-81

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REWORKING THE SERVICE BRAKE ON CERTAIN 416F2 AND 420F2 BACKHOE LOADERS
3155		PS53684

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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 "PS53684" 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 13Feb2018 (Revised 31Jul2018) Service Letter. Changes have been made to the Parts Needed to update the new disc clutches part numbers 5609542/">560-9542 and 5609543/">560-9543 which contains a new brake lining material.

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TERMINATION DATE

29Feb2020

PROBLEM

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The existing rear axle service brake can prematurely wear out on certain 416F2 and 420F2 Backhoe Loaders.

AFFECTED PRODUCT

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Model	Identification Number
416F 2	LBF01000-01192, 1194-1195, 1197-1293, 1295, 1298-1321, 1325, 1331-1334, 1336-1522, 1524-1655, 1657-1763, 1771, 1774-1838, 1840, 1842-2013, 2015-2086, 2089-2090, 2093-2173, 2175, 2177-2413, 2415-2417, 2419-2437, 2439-2444, 2446-2550, 2552-2558, 2560-2561, 2564, 2566-2568, 2571, 2574-2588, 2590, 2592-2808, 2811-2814, 2816-2931, 2933-2940, 2942-3053, 3055, 3058-3075, 3077-3081, 3083-3189, 3191, 3193-3237, 3239-3310, 3314-3477, 3480-3481, 3483-3536, 3538-3553, 3555-3644, 3646-3651, 3653-3668, 3670-3697, 3700-3706, 3708, 3710-3779
420F 2	LBS00150-00924

PARTS NEEDED

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Qty	Part Number	Description
2	2M9780	SEAL-O-RING-STOR
4	7X5762	SEAL-O RING
2	1104755	RING
2	4826728	RING-SLOTTED
1	4826732	DISC-CARRIER
1	4826800	O-RING
1	4826801	O-RING
2	4900021	RING-BACKUP
2	4900022	RING-BACKUP
2	4900029	RING
8	4900397	SEAL-O-RING
8	4900400	DISC-CLUTCH
3	5609542	DISC-CLUTCH
3	5609543	DISC-CLUTCH
1	BULK_OIL	MTO OIL - 17.3 LITERS
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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If the existing rear axle fails, it will need to be reworked. Refer to Image1.

Rework the service brake on both sides. If an axle is repaired and a new spacer is installed, the opposite side must also have the new spacer installed. The running clearance has increased to increase brake life and if the opposite side is not changed, the braking force will not be applied evenly to both sides.

Provide CPI feedback thru SIMSi referencing CPI #385589. The following information must be provided:

1. Machine Serial Number and SMU
2. Axle Serial Number and SMU
3. Pictures from 482-6743 LH Brake Discs and 482-6753 RH Brake Discs, 490-0400 Outer Discs, 482-6732 Mount Disc Carrier, and 482-6734 Slide.
4. Any other information

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Image1

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%
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 10.0-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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Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Refer to the Service Manual if/as necessary.

Refer to Media Number UENR5021, Disassembly and Assembly, 415F2, 416F2, 420F2 IT, 420F2 ST, 430F2 IT and 430F2 ST Backhoe Loaders Power Train, sections:

- Axle Housing, Axle Shaft, and Wheel Flange ? Remove
- Axle Housing, Axle Shaft, and Wheel Flange - Install
- Axle Housing (Service Brakes, Differential and Bevel Gear) - Disassemble - ZF Axle
- Axle Housing (Service Brakes, Differential and Bevel Gear) - Assemble - ZF Axle

Refer to Media Number UENR5023, Testing and Adjusting, 415F2, 416F2, 420F2 IT, 420F2 ST, 430F2 IT and 430F2 ST Backhoe Loaders Axles, Differential and Brakes, sections:

- Service Brake Control ? Adjust
- Brake System Air ? Purge

Refer to Media Number SEBU9212, Operation and Maintenance Manual, 416F2, 420F2 and 430F2 Backhoe Loaders, section:

- Differential Oil (Rear) ? Change

Rework Procedure:

1. Use a grinder to smooth out the grooves and marks on the housing. Refer to Image1.2.1.

Image1.2.1

2. Refer to Image1.3.1 for a view of the assemble parts.

Legend:

(1) 482-6791 Axle Housing
(2) 490-0022 Back-up Ring
(3) 110-4755 Grooved Ring
(4) 482-6784 Piston
(5) 482-6741 Cup Spring
(6) 482-6780 Ring (PREVIOUS) 490-0029 Ring (NEW)
(7) 490-0401 Retaining Ring
(8) 482-6796 Washer
(9) 482-6740 Slotted Pins
(10) 482-6742 Cup Spring
(11) 482-6797 Washer
(12) 490-0021 Back-Up Ring
(13) 482-6728 Grooved Ring

Image1.3.1

3. Insert back-up ring (2) and grooved ring (3), back-up ring (12) and grooved ring (13), into the annular groove (arrow) of axle housing (1). Refer to Image1.4.1.

IMPORTANT - Pay attention to the installation position of the sealing elements.

Image1.4.1

4. Install flush-mount slotted pins (9) (front face) into piston (4). Refer to Image1.5.1.

Image1.5.1

5. Locate cup spring (10), paying attention to the correct installation position, and washer (11) into axle housing (1). Refer to Image1.6.1.

Image1.6.1

6. Oil grooved rings and sealing surfaces of axle housing and piston. Mount pre-assembled piston (1). Refer to Image1.7.1. Push the piston to contact position using a two-armed puller and a pressure plate. Refer to Image1.7.1.

Note: Pay attention to the slotted pins placed in the piston. Ensure that position of located slotted pins does not change. The pressure plate may only touch the piston front face.

Image1.7.1

7. Mount cup spring (5), paying attention to the correct installation position, and washer (8) on to ring (6).Press down cup spring preload using a press, and snap inretaining ring (7). Refer to Image1.8.1.

Image1.8.1

8. Adjust the service control brake.

9. Purge the air from brake system.

10. Add oil to the differential.

Notes:

- For LBF and LBS machines, Cat MTO is the only type of oil recommended.

- For LBS and LBF machines, DO NOT USE oil additive. There is no need to fill the rear axle final drives, there is a communication channel between the differential and final drives.

Note: The oil change interval should be decreased to 500 hours if more than 50% of the service hours is used for roading and loading.