PRODUCT IMPROVEMENT PROGRAM FOR BLEEDING THE SERVICE BRAKES ON CERTAIN 416E BACKHOE LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR BLEEDING THE SERVICE BRAKES ON CERTAIN 416E BACKHOE LOADERS [REBE1063]

BRAKING SYSTEM

BRAKE GP

PRODUCT IMPROVEMENT PROGRAM FOR BLEEDING THE SERVICE BRAKES ON CERTAIN 416E BACKHOE LOADERS

REBE1063-00

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17Jul2006

U-558

A-543

O-542

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR BLEEDING THE SERVICE BRAKES ON CERTAIN 416E BACKHOE LOADERS
4269 4291 3282		PI10521

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10521" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10521" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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PROBLEM

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Certain 416E Backhoes may have been assembled with a small amount of water in the brake system. When the brake housing reaches elevated temperatures, the brakes may fade.

AFFECTED PRODUCT

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Model

Identification Number

416E

CBD00942-00945, 947-953, 955-1008, 1010-1025, 1027-1030, 1033, 1035-1043, 1045-1046, 1049-1050, 1052, 1054-1055, 1062, 1064-1065, 1067-1068, 1070-1074, 1076, 1078-1081, 1083, 1086-1095, 1097-1110, 1112-1126, 1128-1133, 1135-1136, 1139, 1143-1145, 1147-1150, 1154, 1156, 1160, 1163, 1166-1167, 1172-1174

SHA00116-00258, 260-434, 436-464, 467-503, 506, 508-509, 512-513, 516-520, 522-556, 558-566, 568-574, 576-585, 588-596, 598-599, 601, 603-604, 608, 610-629, 634, 637-642, 644-645, 647-655, 657-673, 675-694, 696-697, 699-706, 708-710, 712-718, 721-722, 724-732, 734-740, 742-743, 745, 747-750, 752-754, 756-758, 760, 762-774, 777, 780, 782-787, 789-802, 806-807, 810, 813-822, 824, 826, 829, 831, 833, 836-841, 843-851, 853, 855, 857-858, 860-863, 865, 875, 877, 879, 881, 883, 886-892, 894, 897-898, 901, 903-905, 908-915

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Before Failure: The machine may have a small amount of water in the brake system. Use the attached procedure to check for brake fade and bleed the brakes if necessary. Use "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.

After Failure: If the customer complains of brake fade during operation, use the attached procedure to verify brake fade and bleed the brakes. Use "96" as the Warranty Claim Description Code and "Z" as the SIMS Description Code.

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OWNER NOTIFIAVSION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCTCT IMPROVEMENT PROGRAM FOR BLEEDING THE SERVICE BRAKES ON CERTAIN 416E BACKHOE LOADERS

MODELS INVOLVED - 416E

Dear AVSpare Product Owner:

The service brakes need to be checked and may need to be bled. It is possible that a small amount of moisture may be present in the oil in the rear axle service brake slave cylinders. Brake fade may be experienced when service brakes are operated, if the axle temperature gets high enough to vaporize the moisture, typically above 100 degrees centigrade. If this condition exists, brake fade may occur and may result in personal injury or death. The brakes need to be bled on the products listed below. You will not be charged for the service performed.

Contact your local AVSpare dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 17Jul2006 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

AVSpare Inc.

Identification #(s)

Attached to 17Jul2006 Service Letter

Rework Procedure

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Perform the BRAKE FADE CHECK procedure to determine if brake fade occurs. Brake fade is evident if any pedal sinks to the floor without stopping the wheels when applying the brakes . If brake fade is evident at any time during the test, stop and perform the HOT BLEED PROCEDURE. If no brake fade is evident during the tests, no further action is required.

Equipment Needed:

148-2400 Temperature gun
Brake bleed kit (0.5-liter container and clear heat resistant tube with check valve for attachment to bleed screw)
13mm wrench for bleed screw
Protective clothing: facemask, gloves, and welding jacket or sleeves
Jack stands for placement underneath rear axle or swing casting

BRAKE FADE CHECK:

WARNING: Personal injury may result from not following the specified procedure. To avoid personal injury, follow the procedure as specified.

1. Place the machine on firm ground (concrete), raise machine on stabilizers and loader bucket ensuring that the front and rear tires are completely off the ground. Support the machine on suitable stands.
2. Run the machine at high idle in 3rd forward gear and apply brakes periodically (3-5 seconds on, 3-5 seconds off) to increase the temperature of the front axle and brake housing to the range of 130 - 140 degrees C.
3. To avoid excessive wear on the brake linings, desired temperature range should be reached within 30 minutes.

NOTE: Measure the temperature on the brake axle housing, just below the axle fill plug using the temperature gun as shown in Image 1.

Image1.2.1

4. After reaching 130 degrees C, maintain axle temperature between 130 ? 140 degrees C for approximately 10 minutes by applying the brakes less frequently (for example: 3-5 seconds on, 30 seconds off). Carefully monitor the axle temperature so as not to exceed 140 degrees C.
5. Reduce engine speed to 1200 - 1500 rpm with machine in 3rd forward gear but DO NOT operate the brakes for a period of 2 minutes, (to allow brake system to return to atmospheric pressure). After 2 minutes, apply the brakes together and then individually to check for brake function.
6. If the brakes do not fade, repeat steps 4 and 5 for 30 minutes.
7. Remove the stands and return machine to ground.

Note: Before roading, become familiar with the emergency brake location and function in the event of service brake loss.

8. Road the machine for 20 minutes while maintaining a brake axle housing temperature between 110 and 130 degrees C. Periodically stop the machine, engage parking brake, neutralize transmission, and DO NOT operate the service brakes for a period of 2 minutes. After 2 minutes, apply the brakes together and then individually to check for brake function.

If no brake fade is evident after all testing is completed, no further action is required.

HOT BLEED PROCEDURE:

WARNING: Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Do not allow hot components to contact the skin.

NOTE: Care must be taken to ensure that fluids are contained during inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before operating any component or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

Before the hot bleed procedure is performed, change the oil in the reservoir using the following steps.

1. Obtain clean SAE 10W hydraulic fluid from a sealed container without contamination by any water or chemical. Any water or volatile chemical can cause brake failure.
2. Remove brake reservoir from tractor tower and bracket.
3. Empty reservoir contents.
4. Fully clean reservoir and cap with a contact cleaner or brake cleaner, and ensure there is no residual chemical left in the reservoir.
5. Reinstall the brake reservoir in the bracket on the tractor tower.
6. Refill brake reservoir with clean hydraulic fluid.
7. Reinstall the brake reservoir cap.

To begin hot bleed procedure:

1. Start the engine.
2. Park the machine on level ground, lower stabilizers and loader bucket. Lift the backhoe loader tires several inches off of the ground, while keeping the machine level. Place stands underneath the rear axle for safety.
3. Stop the engine.
4. Remove the dust caps from the bleed screws.

The following procedure must be done with the temperature of the brake housing between 115 and 140 degrees C and the engine stopped.

1. Locate the left and right brake bleed screws on the top side of the rear axle.
2. Install a bleed kit (with high temperature hoses and a check valve) and attach hose to the appropriate bleed screw. Run tube from bleed screw into container below the level of the axle, this should contain some oil and the tube should be below the surface of this oil to avoid air being drawn back into the brake system.

NOTE: Depending on the type of tubing used the high temperature of the oil may relax the tube fit over the bleed screw which could detach during bleeding. A small clip or tie wrap should be sufficient to hold the bleed tube in place during bleeding.

3. Fully press and hold left brake pedal.
4. While holding left brake pedal down, fully stroke the right pedal repeatedly to build pressure.

Warning: Hot oil and water will escape bleed screw when it is opened. Do not allow hot oil or water to contact the skin.

5. Keeping both pedals held down, open bleed screw on right brake side of the machine. Right pedal will fall to floor. If boiling water or vapor is observed, leave bleed screw open until boiling ceases (this may take several minutes).
6. Close bleed screw before releasing pedals.
7. Repeat steps 3-6 until no boiling water or vapor is observed when bleed screw is opened. Ensure all air is bled from axle.
8. Refill the brake reservoir if fluid drops below the minimum level mark.
9. Repeat steps 2-8 for left brake side of the machine using opposite pedals (by holding the right pedal down and pumping the left pedal).
10. When complete, replace the dust caps on the bleed screws.
11. Repeat Brake Fade check procedure to verify all moisture has been purged from the axle. It is common that the Hot Bleed Procedure may need to be repeated several times.

After all tests have been completed, refill brake reservoir to the correct level. Test brakes per Operation and Maintenance Manual, SEBU7970, "Service Brake Holding Ability Test".

For any questions regarding this process, contact the AVSpare Delear Solution Network.