PRODUCT SUPPORT PROGRAM FOR REPLACING SWING CYLINDERS ON CERTAIN 424 II BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING SWING CYLINDERS ON CERTAIN 424 II BACKHOE LOADERS

Usage:

TEBE1805-00

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05Aug2014

D-410

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING SWING CYLINDERS ON CERTAIN 424 II BACKHOE LOADERS
5105		PS52728

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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 "PS52728" 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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TERMINATION DATE

31Jan2016

PROBLEM

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The cushioning plunger can be broken in the swing cylinder on certain 424 II Backhoe Loaders.

AFFECTED PRODUCT

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Model	Identification Number
424 II	JRC05501-05519, 5859-5990, 5997-6682, 6685-6845

PARTS NEEDED

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Qty	Part Number	Description
8	6V8398	SEAL-O-RING-ORFS
1	1780094	FILTER GP-O(BSC)
2	3197198	CYL GP-100 249 X
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Note: This program only covers the broken swing cylinder cushioning issue only. Other failures pertaining to swing cylinders are not applicable.

1. Confirm that the swing cylinder failure is due to a broken cushioning plunger.

2. Refer the attached Rework Procedure.

3. Send failed cylinders to:

WIPRO ENTERPRISES LIMITED, PLOT C-1, SIPCOT INDUSTRIAL PARK, SRIPERUMBUDUR-602105, for warranty approval.

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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%
0-5000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 12.0-hour job
Note: Hydraulic oil lost during the cylinder and filter change can be claimed through this Service Letter.

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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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This Rework Procedure covers the replacement of failed swing cylinder, in the field, with a cushioning plunger failure. Refer to Image1.1.1.

Image1.1.1

TOOLS REQUIRED:

Image1.2.1

DISASSEMBLY PROCEDURE:

1. Park the machine on the level ground.

2. Place the bucket parallel to the ground and keep the front tire touching the ground. Ensure both rear tire and stabilizer are on the ground. Refer to Image1.3.1.

Image1.3.1

3. The Backhoe structure should be center positioned and be resting on the ground. Refer to Image1.4.1.

4. Turn off the engine.

5. Release the hydraulic system pressure and follow instructions before removal of cylinders. Refer to the Operation and Maintenance Manual, for your machine, for additional information.

Image1.4.1

6. Disconnect hose assembly (1) and (2), rod and base end hose, of defective cylinder. Disconnect the swing tube, on both sides, from the vertical bracket. If one cylinder is found defective change the other cylinder also following same procedure as shown below. Refer to Image1.5.1.

Image1.5.1

7. Remove dowel (7) and bolts (3) from the bracket assembly. If necessary, use a suitable lifting device in order to secure the bracket assembly out of the way. Remove bolts (4) and cap (5). Refer to Image1.6.1.

Image1.6.1

8. Remove bolt and nut (9). Remove retaining ring (6) and pin (7). Attach a suitable lifting device in order to remove swing cylinder (8). Refer to Image1.7.1.

Image1.7.1

9. Inspect the valve bank (swing) for the spool damage and contamination. If required, disassemble the valve bank and replace it. Repeat the same procedure for other valve banks in DCV (digger control valve), if required.

10. Replace any hydraulic oil lost during the cylinder and filter change.

11. Replace the hydraulic filter.

ASSEMBLY PROCEDURE:

1. Install new swing cylinder (8) in the reverse order of how it has disassembled. Refer to Image1.9.1.

Image1.9.1

a. Tighten nut (9) to a specified torque of 50 +/- 10 N.m.

b. Tighten nut (10) to a specified torque of 540 + 40 N.m.

c. Ensure proper machine operation.