PRODUCT SUPPORT PROGRAM FOR REWORKING THE INNER EXTENDABLE STICK ON CERTAIN 416F2 AND 420F2 BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE INNER EXTENDABLE STICK ON CERTAIN 416F2 AND 420F2 BACKHOE LOADERS

Usage:

TEBE6714-00

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26Sep2017

U-496

A-350

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REWORKING THE INNER EXTENDABLE STICK ON CERTAIN 416F2 AND 420F2 BACKHOE LOADERS
6533		PS53573

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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 "PS53573" 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

30Sep2019

PROBLEM

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Machines equipped with the extendable stick may crack at inner stick, specifically on the boom to stick joint, on certain 416F2 and 420F2 Backhoe Loaders.

AFFECTED PRODUCT

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Model	Identification Number
416F 2	LBF01031, 1035-1036, 1039, 1042, 1046-1047, 1051, 1054-1057, 1061-1063, 1073-1074, 1120-1125, 1171, 1192, 1231-1234, 1382, 1384, 1386, 1388, 1473-1475, 1483, 1486-1487, 1513, 1515-1517, 1522, 1530-1531, 1533-1534, 1536, 1539, 1606, 1672, 1675, 1678, 1681, 1709, 1711-1713, 1725-1726, 1734, 1792, 1812-1813, 1815, 1817, 1823-1826, 1858-1860, 1862-1863, 1866, 1898, 1917, 1920, 1923, 1950, 1956, 1959-1960, 1962, 1965, 2051, 2055, 2085, 2101, 2104, 2108, 2110, 2154, 2158, 2168, 2172, 2201, 2207, 2221-2222, 2226, 2229, 2236-2237, 2248, 2251, 2263, 2265, 2267, 2269, 2271, 2273, 2288, 2352, 2355, 2357, 2362, 2368, 2371, 2380, 2383, 2393, 2396, 2398, 2401, 2405, 2408, 2411, 2456, 2458, 2498, 2525, 2533, 2550, 2553, 2561, 2564, 2577, 2580-2581, 2583-2585, 2613, 2624, 2627, 2630, 2634, 2638, 2645, 2663, 2669, 2687, 2693, 2700, 2714-2715, 2722, 2732, 2766, 2774, 2777, 2780, 2817, 2820-2821, 2824-2825, 2827, 2830, 2833, 2835, 2838, 2866, 2868, 2871, 2874, 2880, 2883, 2891, 2901, 2915, 2920-2921, 2927-2928, 2974-2976, 2978, 2981, 3000, 3002, 3022, 3028
420F 2	LBS00150, 153, 159, 161-162, 171-175, 177, 179, 183-199, 203-204, 208, 210-211, 226-227, 229-230, 232, 234-242, 251, 253-254, 256-266, 268-305, 307-308, 310-331, 333-335, 337, 342, 347, 352-355, 357, 359, 361-362, 364-377, 380-389, 394, 397, 404, 413, 428-429, 432-441, 443, 446-448, 450, 455, 461-487, 489-517, 519-520, 524-541, 543-545, 547-549, 552-563, 567, 575-577, 579-596, 605-623, 626-635, 637, 640, 642-645, 647-648

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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In the event of failure and if the crack has not gone into the parent material the weld can be removed and replaced.

Refer to Image1 for the failure location and examples of the parent material not affected.

Refer to the attached Rework Procedure.

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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%
0-2500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2501-5000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 15.0-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 UENR5026, Disassembly and Assembly, "Extendable Stick - Remove and Install".

Refer to REHS1841, Special Instruction, "General Welding Procedures", and SEBD0512, Reuse And Salvage Guidelines, "Caterpillar Service Welding Guide", before proceeding through the next steps.

Refer to Image1.2.1.

Image1.2.1

Welding Instructions:

1. Identify the weld area to be removed. Refer to Image1.3.1.

Image1.3.1

2. Remove any components that prevent access to the cracked weld.

3. Protect the machine surfaces from sparks and weld deposits.

4. Remove the paint from the welding to be reworked with a grinder.

5. Use an air carbon arc torch to remove the weld completely all around the boss. Refer to Image1.4.1.

Image1.4.1

6. Inspect the area of the crack to ensure that the crack is removed.

7. Clean the area that will be welded. Ensure that the substances that follow are removed from the area that will be welded. (Oil, Grease, Paint, Dirt).

Image1.5.1 - Weld Requirements:

Dimension (A) 12.0mm (0.47in)
Dimension (B) 39.75mm (1.565in)
Dimension (C) 10.0mm (0.39in)
Dimension (D) 12.0mm (0.47in)
Dimension (E) 10.0mm (0.39in)

Image1.5.1

8. Perform welding (F) (10mm (1/2 V) weld, flat position) as shown in Image1.6.1. Clean the weld and inspect the weld. The weld must be free from the following: cracks, porosity, undercut, and incomplete fusion.

Image1.6.1 - Weld Requirements:

(F) 10mm (1/2 V) weld, flat position

Image1.6.1

9. Perform welding (G) 14mm (0.6in) fillet weld, horizontal position as shown in Image1.7.1. Clean the weld and inspect the weld. The weld must be free from the following: cracks, porosity, undercut, and incomplete fusion.

Image1.7.1 - Weld Requirements:

(G) 14mm (0.6in) fillet weld, horizontal position

Image1.7.1

10. Remove the paint from the welding to be reworked with a grinder.

11. Use an air carbon arc torch to remove the weld completely. Refer to Image1.8.1.

Note: The gouged area must be cleaned by grinding to remove both the carbon deposits and slag.

12. Remove the weld between (J) and (N) points.

13. Inspect the area of the crack to ensure that the crack is removed.

14. Clean the area that will be welded. Ensure that the substances that follow are removed from the area that will be welded. (Oil, Grease, Paint, Dirt).

Image1.8.1 - Weld Removal Dimensions:

Dimension (H) 50mm (2.0in)

Image1.8.1

15. Perform fillet weld (S) 8mm (0.3in) between (P) to (R) in horizontal position as shown in Image1.9.1. Clean the weld and inspect the weld. The weld must be free from the following: cracks, porosity, undercut, and incomplete fusion.

Image1.9.1 - Weld Requirements:

Fillet weld (S) 8mm (0.3in) between (P) to (R)

Image1.9.1

16. Perform fillet weld (V) 12mm (0.5in) multi-pass between (T) to (U) in horizontal position as shown in Image1.10.1. Clean the weld and inspect the weld. The weld must be free from the following: cracks, porosity, undercut, and incomplete fusion.

Image1.10.1 - Weld Requirements:

Fillet weld (V) 12mm (0.5in) multi-pass between (P) to (R)