PRODUCT SUPPORT PROGRAM FOR REWORKING THE STICK PIN BORES ON CERTAIN 415F2, 416F2, AND 420F2 BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE STICK PIN BORES ON CERTAIN 415F2, 416F2, AND 420F2 BACKHOE LOADERS

Usage:

TEBE7833-01

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29Aug2018

(Revised 09May2019)

U-511

A-373

D-448

O-451

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REWORKING THE STICK PIN BORES ON CERTAIN 415F2, 416F2, AND 420F2 BACKHOE LOADERS
6501		PS53855

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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 "PS53855" 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 29Aug2018 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Aug2020

PROBLEM

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The existing boom to stick pin or bearings can fail on certain 415F2, 416F2, and 420F2 Backhoe Loaders. If the existing pin or bearings fail, they will need to be replaced and the stick (extendable or standard) may need to be line bored.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
420F 2	HWC00150-03239, 3241-3247, 3249-3251, 3254-3870, 3872-4995 LYB00150-00466, 468-641
420F 2 IT	HWD00150-02573, 2575, 2578-2579, 2584, 2587-2589, 2595, 2597-2599, 2601-4050 LYC00150-00419, 421, 423-763

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*****Group 2*****
415F 2	HWA00150-00843, 50177
416F 2	HWB00150-01456, 1459, 1461-2177 LYA00150-00478

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3B8489	ADAPTER-STR
1	8T4192	BOLT-HEX HEAD
1	8T4895	WASHER-HARD
3	9R8292	SPACER
2	2136683	BEARING-SLEEVE
1	4730238	PIN AS
2	4730240	PLATE
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.
*****Group 2*****
1	3B8489	ADAPTER-STR
1	8T4192	BOLT-HEX HEAD
1	8T4895	WASHER-HARD
2	9R0170	BEARING-SLEEVE
3	2863086	SPACER
1	4730239	PIN AS
2	4730240	PLATE
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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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%
*****Group 1*****
0-500 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
501-1000 hrs, 19-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 17.0-hour job for Group 1

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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%
*****Group 2*****
0-500 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
501-1000 hrs, 19-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 17.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Remove the stick from the machine according to UENR5026, Disassembly and Assembly, "Extendable Stick - Remove and Install".

Fully remove the walked out/damaged/worn bearings using Puller Tool C. Refer to Images1.1.1 and 1.1.2.

Image1.1.1

Image1.1.2

Preparing the Pin Bores for Repair

Image1.2.1

Inspection of the Pin Bores:

1. Clean the areas around the pin bores.

2. Inspect all the pin bores.

3. If a pin bore is worn or elongated, remove the part from the machine. Refer to your machine's Service Manual for disassembly instructions.

4. Once the part is removed from the machine, clean the pin bores. Refer to the
"Preparing the Pin Bores for Repair" section of this Rework Procedure.

5. Inspect the pin bores. Pin bores must be inspected prior to any machining or welding. Cracks will occur in the thinner sections around the pin bores. For a quality repair, all cracks must be removed prior to machining. To locate cracks in a pin bore, use a dye penetrate or a magnetic particle inspection process. Surfaces should be cleaned and any surface irregularities must be removed before you inspect the parts.

6. Cut out defects to a depth of 6mm (0.24in) beyond the bottom of the defect. Refer to "Machining Elongated Bores" in this Rework Procedure.

Machining Elongated Bores:

Metal to metal contact of the pin bore to any frame member can result in material deformation. Machining prior to welding results in a concentric bore. Machining also stabilizes the base material for welding.

A vertical or horizontal mill can be used for machining the bores. Single point tooling is normally used for cutting the bores to specified dimensions.

Caterpillar recommends using the following carbide cutting tools:

C5 for a rough cut
C7 for a smooth surface finish

Set the speed of the spindle between 380 RPM to 600 RPM. The speed of the spindle must not exceed 600 RPM. The feed rate for the spindle is 0.15 to 0.25mm (0.006 to 0.01in).

For completing repairs in the field, Caterpillar recommends using the 1U-8660 Boring Bar. The hydraulic boring bar is equipped with several attachments. The attachments are needed in order to machine the pin bores to the correct dimensions.

The 1U-8660 Boring Bar can be set up in order to allow machining and welding without adjusting the 1U-8660 Boring Bar.

Applying Welds to a Pin Bore:

Once the machining is finished, the metal must be prepared for welding. Follow the instructions below in order to correctly apply welds to the pin bores.

Welding Procedures:

1. Clean the pin bore. The area around the pin bore must also be cleaned. Refer to "Preparing the Pin Bores for Repair" in this Rework Procedure.

2. Inspect the pin bore. If a defect is found, remove the fault by cutting or machining. Refer to "Machining Elongated Bores" for instructions in order to eliminate the fault.

3. Preheat the base metal of the pin bore to a temperature of 95 +/- 10 degrees Celsius (203 +/- 18 degrees Fahrenheit). Preheating the metal will prevent cracking of the base metal. Preheating will also reduce the chances of hydrogen embrittlement.

4. Use an automated 1U-9600 Welding Group in order to correctly build up a pin bore with welds. Automated welding will result in clean, even metal deposition. The 1U-9600 Welding Group offers improved performance over SMAW and GMAW welding systems. If the 1U-9600 Welding Group is not available, you can use an E7018 SMAW electrode. The E7018 SMAW electrode has a diameter of 3.18mm (0.13in). If an E7018 SMAW electrode cannot be found, you can also use a 1U-5232 Welding Rod or GMAW welding. Refer to Table 1 in Image1.6.1 for the welding parameters.

Image1.6.1

Note: The 1U-9600 Welding Group (60 Hz) is not sold in Europe. The 1U-9601 Welding Group (50 Hz) is sold in Europe only. The 1U-9601 Welding Group (50 Hz) can replace the 1U-9600 Welding Group (60 Hz).

5. Apply weld (A) to each of the pin bore. Refer to Illustration 1 in Image1.8.1.

Note: Before you begin to weld on the pin bore, preheat the metal to 95 degrees Celsius (203 degrees Fahrenheit).

6. Apply multiple welds (B) to the length of the pin bore. The welds must connect the welds which outline the pin bore. Refer to Illustration 1 in Image1.8.1.

Note: Allow the welds to slowly cool. Repair any welds by removing the existing weld. Apply a weld to the area which is being repaired. Before you begin welding again, you must preheat the pin bore.

7. Machine the welds to the dimensions shown below according to the model.

Image1.8.1

420F2 and 420F2 IT Machines: Location of boom to stick pin bore relative to stick cylinder rod eye pin bore. Reference dimensions only. Refer to Image1.9.1.

Image1.9.1

420F2 and 420F2 IT Machines: Bearing bore dimensions for the boss on e-stick inner for bearings. Refer to Image1.10.1.

Image1.10.1

420F2 and 420F2 IT Machines: Final dimensions with 213-6683 Bearings installed. Refer to Image1.11.1.

Image1.11.1

415F2 and 416F2 Machines: Location of boom to stick pin bore relative to stick cylinder rod eye pin bore. Reference dimensions only. Refer to Image1.12.1.

Image1.12.1

415F2 and 416F2 Machines: Bearing bore dimensions for boss on the e-stick inner for bearings. Refer to Image1.13.1.

Image1.13.1

415F2 and 416F2 Machines: Final dimensions with 9R-0170 Bearings installed. Refer to Image1.14.1.

Image1.14.1

Protecting the Welds:

New welds must be painted. Paint will protect the welds against rusting. Paint the welds with an authorized Caterpillar paint. The paint will help prevent rust from forming on the new welds. Refer to the following instructions for preparing the welds for painting and for painting the welds.

Finishing the Welds and Painting the Welds:

1. Protect all finished bores. Cover the bores in order to prevent paint and other material from entering the bores.

2. Grind all the welds to a smooth finish.

3. Remove any spatter from the surrounding areas around the welds.

4. Shot blast the welds and surrounding areas prior to painting.

5. Paint the welds with a paint that is approved by Caterpillar.

6. Remove all protective outer coverings from the bores.

7. Inspect the grease passages for obstructions before you install new bearings. If the grease passages become blocked, the grease which is used to lubricate the bearings will not reach the bearings. Failure to lubricate the bearings will result in damage to the bearings.