PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW DOOR GP ON CERTAIN 424B BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW DOOR GP ON CERTAIN 424B BACKHOE LOADERS

Usage:

TEBE3744-00

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15Oct2015

D-472

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW DOOR GP ON CERTAIN 424B BACKHOE LOADERS
7308		PS53051

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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 "PS53051" 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

31Oct2016

PROBLEM

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The existing 4232411/">423-2411 LH Door Group and 4241044/">424-1044 RH Door Group with 432-7475 Plate Assembly can open automatically during a jerky machine operation on certain 424B Backhoe Loaders. New door groups with a new striker pin are now used address the door lock issue field complaints.

AFFECTED PRODUCT

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Model	Identification Number
424B	JRN01000-01100, 1102-2420
424B HD	JRY01000-01051

PARTS NEEDED

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Qty	Part Number	Description
4	8T4138	BOLT-HEX HEAD
4	9X8256	WASHER
1	4232411	DOOR GP-LH
1	4241044	DOOR GP-RH
1	4913332	PIN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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Dealers must use this program with proper judgment. Field Service Technical Rep approval is required for this Service Letter program to be completed and before parts are ordered.

Only the cabin door lock opening issue complaints can use this Service Letter program. All other door reliability issue claims will not be entertained through this Service Letter program.

Dealer can replace only the failed door group on any particular machine, not both doors.

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, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.0-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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Rework Procedure for Replacement of the Door Group for the 424B Cab Door Lock Issue:

Note: Please read all of the steps before start of this Rework Procedure.

Note: The operator should wear a helmet, gloves, safety glasses, ear protection, and safety shoes, while completing this Rework Procedure.

1. Park the machine on a level surface. If you must park on a grade, chock the machine.

2. Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.

3. Move the speed control lever to the LOW IDLE position.

4. Engage the parking brake.

5. Engage the transmission neutral lock.

6. Lower all work tools to the ground.

7. Stop the engine using engine shut-off cable.

8. Move the hydraulic control levers back and forth in order to relieve hydraulic pressure. Refer to the Disassembly and Assembly, "System Pressure - Release", for additional information.

9. Turn the engine start switch to OFF position and remove the key.

Required Parts:

4232411/">423-2411 Door Group-LH - 1 Qty (Use only when LH Door failed)
4241044/">424-1044 Door Group-RH ? 1 Qty (Use only when RH Door failed)
491-3332 Pin - 1 Qty per door (When new door groups replaced)
8T-4138 Bolt-Hex Head - (2 Qty per door, if required)
9X-8256 Washer - (2 Qty per door, if required)

Required Tools:

Refer to Images1.1.1, 1.1.2, and 1.1.3.

- Nylon Hammer
- 10mm thickness gauge (Go-No Go type) in any shape
- Ring spanner ? No 10-11
- Ring spanner ? No 12-13
- Nose Plier ? 1
- Small wooden block ? 1
- Use general tools available in tool box

Image1.1.1

Image1.1.2

Image1.1.3

Replacement of the Imported Lock Mounted Door Group:

1. Disassemble the 432-7476 Strap on the failed 4232411/">423-2411 LH Door Group or failed 4241044/">424-1044 RH Door group, from the cabin.

2. Disassemble the 336-3418 Gas Spring from the cabin.

Refer to Images1.2.1 and 1.2.2.

Image1.2.1

Image1.2.2

3. Disassemble the 4232411/">423-2411 LH Door Group or 4241044/">424-1044 RH Door Group from the cabin. Refer to Image1.3.1.

Image1.3.1

4. Remove the 432-7475 Plate Assembly (striker pin) by loosening the plate assembly mounting fasteners. Refer to Image1.4.1.

Image1.4.1

5. Assemble the new 491-3332 Striker Pin in the mounting hole of bracket assembly. Refer to Image1.5.1.

Note: Ensure that the chamfer face is facing outside of cabin.

Image1.5.1

6. Assemble the imported lock mounted 4232411/">423-2411 LH Door Group or 4241044/">424-1044 RH Door Group. Ensure that after the imported lock mounted door group is assembled, check the alignment of latch and striker pin.

7. Apply the required torque on the striker pin bolts.

Refer to Image1.6.1.

Image1.6.1

8. Re-Assemble the gas spring. Ensure that the gas spring rod end is assembled in the cabin frame.

9. Re-Assemble the 432-7476 Strap on the 4232411/">423-2411 LH Door Group or 4241044/">424-1044 RH Door Group on the cabin strap mounting location.

Refer to Image1.7.1.

Image1.7.1

A gap of 10-14mm is required between the L-plate to door when the door is in the closed position so that the beading can squeeze and function as a seal against water entry. This is applicable wherever the seal is fitted straight.

10. After door group fitment, ensure that a required gap of 10-14mm is between the L-plate to door, when door is in closed position. Refer to A.

Ensure that the double lock is fully engages. If required, adjust the plate assembly upside or downside within the plate assembly slot limit to align it to the latch assembly striker and ensure that the latch assembly performs second lock during door lock after the adjustment. Refer to B.

Note: At a closed position the latch and striker pin center alignment should be in-line.

Refer to Image1.8.1.

Image1.8.1

11. If an alignment issue is found at the striker pin and latch assembly, then perform the following adjustment procedure based on the requirement only. Refer to Images1.9.1 and 1.9.2.

12. If required, a grinding and sanding process (max of 2mm) should be completed at the door mounting hinge in order to maintain the center alignment for latch and striker pin.

Required Tools:

- Portable grinding machine
- Sanding wheel (GR 36)
- Grinding wheel (1mm)

Image1.9.1

Image1.9.2

A gap of 10-14mm is required between the L-plate to door when the door is in the closed position so that the beading can squeeze and function as a seal against water entry. This is applicable wherever the seal is fitted straight.

In the case that the gap in between the L-plate on the cabin frame to the door group is less than 10mm, follow the Rework Procedure steps below in order to achieve the 10-14mm gap in between the cabin frame L-plate to door group in rubber beading removed condition. Refer to Image1.10.1.

Image1.10.1

13. Remove the rubber beading from the cabin frame completely. Refer to Image1.11.1.

Image1.11.1

14. Close the door completely and ensure that it is double locked.

15. Inside the cabin use the 10mm gauge and measure the gap in-between the cabin frame and door inner frame as shown in Image1.12.1. Ensure that the gap is measured from A to B as highlighted in Image1.12.1.

Image1.12.1

16. If less than a 10mm gap (not able to insert the gauge) is found during measurement, then use the nylon hammer and a small wooden block to carefully hit the cabin frame on the location where there is less gap. Refer to Image1.13.1.

IMPORTANT: Ensure that no damage occurs to any of the cabin components and door glasses.

17. Continue this process until a 10mm gap is achieved. Refer to Image1.13.2.

Image1.13.1

Image1.13.2

18. Once a 10mm gap is achieved across the required distance, refit the rubber beading back into the door frame and check and ensure that the door can be closed properly with the double lock.