PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXTENDABLE STICK CYLINDER TUBE ASSEMBLY ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXTENDABLE STICK CYLINDER TUBE ASSEMBLY ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS [REBE1579]

HYDRAULIC SYSTEM

LINES GP-STICK

PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXTENDABLE STICK CYLINDER TUBE ASSEMBLY ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS

REBE1579-01

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29Mar2007

(Revised 23May2007)

U-119

A-101

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE EXTENDABLE STICK CYLINDER TUBE ASSEMBLY ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS
5057		PS42371

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42371" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the March 29, 2007 Service Letter. Changes have been made to the Parts Needed and Rework Procedure.

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TERMINATION DATE

31Mar2009

PROBLEM

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Some 416E, 420E, and 430E Backhoe Loaders were built using a hydraulic tube assembly for the rod end of the extended stick cylinder. Cylinder movement may cause the tube assembly to fail, causing leaks. Inspection is required to determine if a tube assembly was installed on the affected machines listed.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
416E	SHA00133-00134, 144-146, 148-150, 153-162, 164, 167, 170, 173-175, 177-178, 181-182, 186-187, 189-190, 192-194, 197, 202, 204-206, 218-220, 222, 225, 232-239, 244-250, 252, 260, 271-274, 276, 281-282, 285-286, 290, 293, 296-298, 305, 313, 315, 319, 324, 326, 331, 374, 378, 380-381, 385-386, 391, 394, 396-399, 402, 405, 407-414, 416, 418, 420-421, 424-425, 429-430, 432-433, 435, 437, 439-444, 447, 449, 452, 454-458, 460, 464-466, 483, 500, 504, 512, 514-515, 521, 524, 533, 537, 539, 544, 559, 562-563, 565, 567, 569, 573, 578, 590, 592, 594-595, 598, 602-604, 606, 609, 614, 618, 622, 628, 630, 633, 636, 640, 643-646, 654, 656-661, 663, 666, 668, 678-681, 683, 685, 690-691, 693-694, 696, 700-702, 704, 712, 715-716, 720, 722, 725, 733, 735, 737, 740, 742-746, 748, 750-755, 757-759, 761-762, 765-766, 776, 779, 781-782, 785, 788, 800, 803, 805, 808, 810-812, 815-817, 823, 825, 827-828, 830, 833-834, 837, 851, 853, 857, 862, 864, 875, 877, 879, 889-890, 892, 894, 897, 903, 908, 912, 915, 919-920, 923-924, 933, 935, 942, 944, 947, 950, 952-954, 956-957, 963-964, 973-974, 976, 979, 981, 983-984, 989, 993-994, 996, 1001, 1011, 1015, 1034, 1040, 1042-1045, 1047, 1058-1060, 1066-1068, 1074-1075, 1082, 1100-1102, 1105, 1115-1116, 1120-1123, 1127-1128, 1131, 1134, 1141-1142, 1144, 1151, 1155, 1164-1167, 1170, 1172-1175, 1179-1197, 1202-1203, 1205, 1208, 1210, 1212, 1216
420E	HLS00219-00228, 231-234, 236-243, 245-246, 248-251, 253-254, 256-263, 265-266, 268-275, 277-279, 281-282, 285-290, 292-302, 304-314, 316-319, 321-342, 344-353, 355-363, 365, 367-369, 371-386, 388, 390-391, 393-405, 407-408, 410-414, 416-418, 421-422, 424-427, 429-435, 437-438, 440-443, 445-450, 452-455, 457-458, 460, 462-480, 482-489, 493, 495, 498-501, 507, 509, 511-513, 516-517, 520, 522-523, 525-527, 538-552, 564-565, 579-580, 582, 584-585, 588, 590, 593-594, 600, 603, 605, 607, 609, 612, 614, 616, 618, 621-622, 625-627, 630-631, 633, 635, 639-640, 643-644, 646-647, 652, 655-656, 658, 662, 667, 669-670, 673-674, 677-679, 681-682, 684-692, 694-696, 699-700, 703, 706, 709-710, 713-718, 720-724, 726-727, 729-730, 732-733, 737-740, 742-747, 750-756, 759, 763-764, 766-770, 772-774, 776-778, 781, 785, 790, 798, 804, 807-810, 812-813, 815-817, 819, 821-822, 824, 827-829, 831-833, 835-838, 840-841, 843-845, 847-848, 851-855, 858, 860-863, 865, 867-869, 873, 876, 878-882, 884, 886, 891, 893, 895, 897-899, 901-910, 916, 919, 924, 926-929, 933, 938-939, 941-942, 944, 946, 951, 954-968, 970, 973-975, 980-984, 987, 989-990, 993, 995-997, 999-1003, 1005-1007, 1009-1010, 1013, 1015, 1017-1018, 1020-1021, 1023-1025, 1027, 1029, 1031, 1033, 1036-1037, 1039-1040, 1042-1043, 1045-1047, 1049, 1053, 1057-1058, 1062-1065, 1068-1070, 1072-1073, 1076, 1081, 1083-1086, 1089, 1091-1092, 1094-1096, 1106, 1110-1111, 1114, 1116-1117, 1119, 1121-1129, 1131, 1133-1134, 1136-1138, 1140, 1142, 1146-1147, 1149-1150, 1152, 1154-1155, 1157-1161, 1164, 1167, 1170-1184, 1187, 1189-1190, 1192-1193, 1195, 1198-1201, 1203, 1205-1206, 1208-1212, 1214-1215, 1217-1222, 1225-1227, 1231, 1233-1235, 1237-1238, 1240-1242, 1245-1246, 1249, 1252-1254, 1256, 1258-1261, 1263-1264, 1266, 1268-1273, 1275-1276, 1278-1282, 1284, 1286-1289, 1291-1293, 1295-1299, 1301-1304, 1306, 1309-1311, 1313-1322, 1324-1326, 1328, 1330-1332, 1334-1335, 1337, 1339-1340, 1342-1343, 1345-1346, 1348-1349, 1352-1353, 1355-1357, 1359-1368, 1370-1371, 1379, 1382-1385, 1387-1389, 1391-1401, 1404-1417, 1419-1428, 1430-1431, 1434-1436, 1438-1440, 1444-1445, 1448-1449, 1451-1452, 1454, 1456, 1459-1460, 1462-1463, 1465-1471, 1473, 1476-1477, 1479, 1481-1483, 1485-1489, 1492-1495, 1497-1505, 1508-1513, 1515, 1517-1525, 1528, 1530, 1532, 1538, 1540, 1542-1547, 1549, 1552, 1556-1560, 1563, 1566-1567, 1571-1573, 1575-1576, 1579-1580, 1582-1585, 1588, 1590-1591, 1593-1595, 1598, 1600-1603, 1605, 1608-1610, 1612, 1616, 1618-1620, 1622, 1624-1625, 1628, 1630, 1632-1635, 1637-1641, 1643, 1645-1647, 1650, 1653-1656, 1659-1661, 1663-1664, 1666-1667, 1670-1677, 1680, 1683-1686, 1688-1690, 1692-1693, 1696-1703, 1705-1708, 1710-1712, 1715, 1717-1719, 1721, 1723-1725, 1728-1729, 1731-1735, 1737, 1739, 1742-1746, 1748-1751, 1753-1754, 1757, 1759-1762, 1764-1766, 1769, 1771, 1774-1777, 1780-1783, 1785-1787, 1793, 1795, 1797, 1800-1803, 1806, 1808-1813, 1816-1819, 1821, 1823-1824, 1826, 1828, 1831, 1835-1837, 1839-1843, 1845, 1847, 1850, 1852-1853, 1856, 1858-1859, 1861, 1863, 1866, 1868-1870, 1873-1874, 1876-1877, 1882, 1884, 1886-1887, 1889, 1893, 1895-1897, 1899-1900, 1902-1904, 1907, 1909, 1911-1912, 1914-1916, 1920-1923, 1927-1933, 1935-1936, 1938-1942, 1944-1949, 1951-1954, 1957, 1959-1962, 1964, 1966-1969, 1972-1976, 1978-1986, 1988, 1991, 1994-1996, 1998, 2002, 2004-2007, 2009-2011, 2013-2015, 2017, 2020-2024, 2026, 2029-2030, 2032-2040, 2043-2049, 2051-2052, 2054, 2057-2068, 2071, 2073-2074, 2077-2091, 2093, 2095-2101, 2103-2167, 2169-2170, 2175-2176, 2178, 2181-2184, 2188, 2192-2196, 2198, 2201-2207, 2209 KMW00163-00201, 203-206, 208-221, 224-229, 231-236, 239-248, 250-255, 257-264, 266-302, 304-305, 308, 311-323, 325-360, 363-367, 370-377, 379-401, 403-404, 406, 408-418, 421-423, 425-427, 429-430, 432-435, 437-444, 447-449, 451-497, 499-538, 540-547, 549-556, 558, 560-563, 565-567, 569, 571-572, 575-576, 578, 580-617, 619-653, 655-660, 663-672, 674-675, 677, 681-686, 688-691, 693, 695-698, 700-703, 705, 708-714, 716-717, 719-726, 728-739, 741-756, 758-763, 765-766, 768-785, 787-793, 795, 797, 800-802, 805-808, 810-813, 815, 817-826, 829, 831, 834, 836-837, 839-841, 843-845, 847-851, 853-854, 856-859, 861-864, 866-868, 870-876, 879-886, 888, 890-891, 893-916, 918-921, 923, 925, 927

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*******Group 2*******

430E

DDT00225-00233, 235-241, 243-268, 270-280, 282-286, 288-296, 298-312, 314-316, 318-338, 341-359, 361-387, 389

EAT00237-00238, 240, 242, 245-246, 248-256, 258-265, 268, 270-297, 299-301, 303, 306-310, 312, 314-316, 318-319, 322-325, 327, 329, 331, 334-338, 340-343, 345-351, 353-354, 356-365, 367-374, 376-380, 382-383, 385, 387-390, 392-398, 400-402, 404-412, 414-418, 420-458, 461-479, 481-485, 487-514, 516-519, 522-530, 532-569, 573

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	7K1181	STRAP-CABLE
2	8T1891	CLIP
2	8T1892	CLIP
3	8T6726	CLAMP-HOSE
3	9R2053	BLOCK
2	2062423	SADDLE
1	2213234	HOSE AS
1	2906023	HOSE AS.
1	2918449	TUBE AS.
1	2918450	TUBE AS.
*****Group 2*****
1	8I0668	HOSE AS
2	8T1891	CLIP
2	8T1892	CLIP
3	8T6726	CLAMP-HOSE
3	9R2053	BLOCK
1	1862425	HOSE AS
1	2918451	TUBE AS.
1	2918452	TUBE AS.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

Before Failure: Defined as replacing the tube assembly with the hose assembly prior to the tube assembly leaking. Use "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.

After Failure: Defined as replacing the tube assembly with the hose assembly after the tube assembly has begun to leak. Use "96" as the Warranty Claim Description Code and "Z" as the SIMS Description Code.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-3750 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 1
Additional 7.0 hours are allowed for repair.

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-3750 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 2
Additional 7.0 hours are allowed for repair.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Inspection is required to determine if the machine is equipped with tube assemblies on the E-stick cylinders. Machines equipped with these tubes require additional rework. Refer to the chart to identify the tube part numbers for each sales model. The tubes can seen by looking into the end of the E-stick inner where the extension cylinder pins to the E-stick inner. If the machine is equipped with hose assemblies on the extension cylinder, no additional rework is required.

Image1.1.1

Group 1

Replace the existing tube assemblies. Refer to the assembly drawing and parts callouts in image 1.2.1 and 1.2.2 for the 416E and the 420E Backhoe Loaders. Position the hose assemblies according to the dimensions in image 1.2.3 and clamp hose assembly along the cylinder to take up any slack. The dimensions in image 1.2.3 are taken from the O-ring surface of the hose assembly to the front edge of the cylinder boss at the head end port.

Image1.2.1

Image1.2.2

Image1.2.3

Group 2

Replace the existing tube assemblies. Refer to the assembly drawing and parts callouts in image 1.3.1 and 1.3.2 for the 430E Backhoe Loaders. Position the hose assemblies according to the dimensions in image 1.2.3 and clamp hose assembly along the cylinder to take up any slack. The dimensions in image 1.2.3 are taken from the O-ring surface of the hose assembly to the front edge of the cylinder boss at the head end port.