PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE STANDARD STICK ON CERTAIN 420E BACKHOE LOADERS EQUIPPED WITH STANDARD STICK Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE STANDARD STICK ON CERTAIN 420E BACKHOE LOADERS EQUIPPED WITH STANDARD STICK [REBE1130]

IMPLEMENTS

STICK GP

PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE STANDARD STICK ON CERTAIN 420E BACKHOE LOADERS EQUIPPED WITH STANDARD STICK

REBE1130-01

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28Aug2006

(Revised 26Oct2006)

U-606

A-589

D-576

O-588

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE STANDARD STICK ON CERTAIN 420E BACKHOE LOADERS EQUIPPED WITH STANDARD STICK
6502		PI10532

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10532" 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 "PI10532" 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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NOTE:	This Revised Service Letter replaces the August 28, 2006 Service Letter. Changes have been made to Problem, Affected Product, and Parts Needed.

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PROBLEM

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The standard stick may catastrophically fail in the general area of the stick and bucket pivot points. The failure may result in uncontrollable movement of the stick and may result in personal injury or death.

AFFECTED PRODUCT

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Model

Identification Number

420E

HLS00230, 235, 244, 247, 252, 255, 264, 267, 276, 280, 284, 291, 315, 320, 354, 364, 370, 387, 392, 406, 409, 415, 419-420, 423, 428, 436, 439, 444, 451, 456, 459, 461, 481, 490-492, 494, 496-497, 502-506, 508, 510, 514-515, 518-519, 521, 524, 528-537, 553-563, 566-578, 581, 583, 586-587, 589, 591-592, 595-599, 601-602, 604, 606, 608, 610-611, 613, 615, 617, 619-620, 623-624, 628-629, 632, 634, 636-638, 641-642, 645, 648-651, 653-654, 657, 659-661, 663-666, 668, 671-672, 675-676, 680, 683, 693, 697-698, 701-702, 704-705, 707-708, 711-712, 719, 725, 728, 731, 734-736, 741, 748-749, 757-758, 760-762, 765, 771, 775, 779-780, 782-784, 786-789, 791-797, 799-803, 805-806, 811, 814, 818, 820, 823, 825-826, 830, 834, 839, 842, 846, 849-850, 856-857, 859, 864, 866, 870-872, 874-875, 877, 883, 885, 887-890, 892, 894, 896, 900, 911-915, 917-918, 920-923, 925, 930-932, 934-937, 940, 943, 945, 947-950, 952-953, 969, 971-972, 976-979, 985-986, 988, 991-992, 994, 998, 1004, 1008, 1011-1012, 1014, 1016, 1019, 1022, 1028, 1030, 1032, 1034-1035, 1038, 1041, 1044, 1048, 1050-1052, 1054-1056, 1060-1061, 1066, 1071, 1077-1080, 1082, 1087-1088, 1090, 1097-1105, 1107-1109, 1112-1113, 1115, 1118, 1120, 1130, 1132, 1135, 1139, 1141, 1143-1145, 1148, 1151, 1153, 1156, 1162-1163, 1165-1166, 1168-1169, 1185-1186, 1188, 1191, 1194, 1196-1197, 1202, 1204, 1207, 1213, 1216, 1223-1224, 1228-1230, 1232, 1236, 1239, 1243-1244, 1247-1248, 1250-1251, 1255, 1257, 1262, 1267, 1274, 1277, 1285, 1290, 1294, 1300, 1305, 1307-1308, 1312, 1323, 1327, 1329, 1333, 1336, 1338, 1341, 1344, 1347, 1350-1351, 1354, 1358, 1369, 1372-1375, 1377, 1380-1381, 1386, 1390, 1402-1403, 1418, 1429, 1432-1433, 1437, 1441-1443, 1446-1447, 1450, 1453, 1455, 1457-1458, 1461, 1464, 1472, 1474, 1478, 1480, 1484, 1490-1491, 1496, 1514, 1516, 1526-1527, 1529, 1531, 1533-1536, 1539, 1541, 1548, 1550-1551, 1553-1555, 1561-1562, 1564-1565, 1568, 1570, 1574, 1577-1578, 1581, 1586, 1589, 1592, 1596-1597, 1599, 1604, 1606-1607, 1613-1615, 1617, 1626-1627, 1629, 1631, 1642, 1651-1652, 1657-1658, 1687, 1694, 1709, 1755-1756

KMW00202, 207, 222, 237, 249, 256, 265, 303, 306-307, 309-310, 324, 361-362, 368-369, 378, 402, 405, 407, 419-420, 424, 428, 431, 436, 445-446, 450, 498, 539, 548, 557, 559, 564, 568, 570, 573-574, 577, 579, 618, 654, 661-662, 676, 679-680, 687, 692, 715

PARTS NEEDED

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Qty	Part Number	Description
1	2995421	PLATE
2	2995508	PLATE
1	3001131	PLATE

ACTION REQUIRED

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See the attached inspection and rework procedure.

Clayton built machines with serial number prefix of "HLS" and "KMW" may be reworked by dealer fabricated plates or by ordering parts [(qty) Part Number] (2)299-5508, (1)299-5421 and (1)300-1131. See "Allowance Table" for the allowance for dealer fabricated plates.

Before Failure: Defined as using the attached rework procedure to rework stick with no crack(s) detected. Use ?56? as the Warranty Claim Description Code and ?T? as the SIMS Description Code.

After Failure: Defined as crack(s) detected or catastrophic failure of the stick. Replace the stick and claim as resultant damage. 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 12.0-hour job
NOTE: An additional $200.00 will be allowed for the dealer to fabricate the reinforcement plates.

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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 - PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE STANDARD STICK ON CERTAIN 420E BACKHOE LOADERS EQUIPPED WITH STANDARD STICK

MODELS INVOLVED - 420E Backhoe Loaders

Dear AVSpare Product Owner:

New reinforcement plates need to be installed on the products listed below. If the reinforcement plates are not installed, the stick may catastrophically fail in the stick and bucket cylinder pivot points. The failure may result in uncontrollable movement of the stick and may result in personal injury or death. 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 28Aug2006 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 28Aug2006 Service Letter

Rework Procedure

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?Procedure for adding reinforcement plates on the 420E backhoe loader standard stick?

Part Number (Description)
299-5508 (Triangle Side Plate)
299-5421 (Saddle Plate)
300-1131 (Filler Plate)

1. Remove the stick from the machine. Refer to Disassembly and Assembly Manual, RENR6485, ?Stick ? Remove and Install?.

Inspecting for Cracks
2. Inspect the stick for any cracks. The crack will appear in or around the weld of the bosses for the bucket and stick cylinders and the stick side plates (shown below). If the stick has any cracks in the area shown below, regardless if it is in the parent material or in the weld, replace the stick with a reinforced reworked stick.

Image1.1.1

Image1.1.2

Removing Existing Paint
3. Place the saddle plate into the stick (using the dimensions shown below) from the bottom with the short leg of the plate going in first. Note: Grinding of the plate may be required for proper fit.
4. Position the saddle plate and mark the areas on the stick where the saddle plate will be welded.

Image1.2.1

Image1.2.2

5. Position the two triangular outer plates into position using the dimensions below and mark areas on the stick where the triangular outer plate will be welded.

Image1.3.1

Image1.3.2

6. Remove the paint on the inner and outer stick for placement of the reinforcement plates.

Welding the Saddle Plate
7. Position the saddle plate according to the dimensions shown below.

Image1.4.1

8. Tack on controls bars in the general locations shown below.

Image1.5.1

9. Tack the saddle plate in the areas shown on both sides of the plate.

Image1.6.1

10. Check to make sure the pins fit in the bores.
11. Weld the saddle plate according to the illustrations shown below.

Image1.7.1

Image1.7.2

Image1.7.3

Image1.7.4

Using the Filler Plate
12. If there is a gap between the saddle plate and pin boss, a filler plate may be used.

Image1.8.1

13. Position the saddle plate so the gap is located between the saddle plate and the inner stick plate. The gap should now be closed between the saddle plate and the pin boss.
14. Position the filler plate to overlay the saddle plate and close the gap.

Image1.9.1

15. Tack the saddle and filler plate according to step 9.
16. Weld the saddle and filler plate according to step 11. Make sure to weld the filler plate to the saddle plate.

Welding the Outer Plates
17. Position the outer plates according the dimensions shown below. (Dimensions are typical for both sides.)