PRODUCT SUPPORT PROGRAM FOR REPLACING THE HOSE ASSEMBLIES ON THE HOE ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HOSE ASSEMBLIES ON THE HOE ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS [REBE2983]

HYDRAULIC SYSTEM

CYLINDER GP

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HOSE ASSEMBLIES ON THE HOE ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS

REBE2983-00

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08Jan2008

U-14

A-11

D-8

O-10

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE HOSE ASSEMBLIES ON THE HOE ON CERTAIN 416E, 420E, AND 430E BACKHOE LOADERS
5456 5057 5457		PS51429

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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 "PS51429" 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 AVSpare product analyst.

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TERMINATION DATE

31Jan2010

PROBLEM

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The existing hose assemblies can wear prematurely on certain 416E, 420E and 430E Backhoe Loaders. Failure of the hose assembly is defined as exposure of the reinforcement wires in the hose due to interference with the swing casting.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
416E	SHA00116-02705

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*****Group 2*****
420E	HLS00210-04357 KMW00150-01729

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*****Group 3*****
430E	DDT00220-00580 EAT00230-00937

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3D2824	SEAL-O-RING
2	6V8398	SEAL-O-RING-ORFS
1	6V8713	CONNECTOR-SEAL
1	6V9170	NUT-BULKHEAD
9	7J9108	SEAL-O-RING
1	1421072	HOSE AS
1	1841131	HOSE AS
1	2042281	TIE-WRAP
2	2310215	HOSE AS.
1	2681547	CONNECTOR
1	2781170	HOSE AS
1	2787793	HOSE AS.
1	2906711	HOSE AS.
1	2906712	HOSE AS.
2	3112498	HOSE AS
3	3112501	HOSE AS
1	3112505	HOSE AS
4	3112519	HOSE AS.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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.
*****Group 2*****
1	3D2824	SEAL-O-RING
2	6V8398	SEAL-O-RING-ORFS
1	6V8713	CONNECTOR-SEAL
1	6V9170	NUT-BULKHEAD
9	7J9108	SEAL-O-RING
1	1421072	HOSE AS
1	2042281	TIE-WRAP
2	2310215	HOSE AS.
1	2681547	CONNECTOR
1	2781170	HOSE AS
1	2906711	HOSE AS.
1	2906712	HOSE AS.
2	3112498	HOSE AS
4	3112501	HOSE AS
1	3112503	HOSE AS
1	3112505	HOSE AS
1	3112518	HOSE AS.
3	3112519	HOSE AS.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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.
*****Group 3*****
1	3D2824	SEAL-O-RING
2	6V8398	SEAL-O-RING-ORFS
1	6V8713	CONNECTOR-SEAL
1	6V9170	NUT-BULKHEAD
9	7J9108	SEAL-O-RING
1	8Y7751	HOSE AS
2	1667302	HOSE AS
1	2042281	TIE-WRAP
1	2372920	HOSE AS
1	2681547	CONNECTOR
1	2906713	HOSE AS.
1	2906714	HOSE AS.
1	3053269	HOSE AS.
2	3112497	HOSE AS
4	3112500	HOSE AS
1	3112512	HOSE AS
1	3112516	HOSE AS.
3	3112517	HOSE AS.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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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Refer to the attached Rework Procedure.

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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*****
0-1000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-2000 hrs, 19-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 3.0-hour job for Group 1
Note: 1 additional hour is allowed for machines equipped with E-stick or auxiliary lines. 2 additional hours is allowed for machines equipped with E-stick and auxiliary lines. Failure of the hose assembly is defined as exposure of the reinforcement wires in the hose due to interference with the swing casting.

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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*****
0-1000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-2000 hrs, 19-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 3.0-hour job for Group 2
Note: 1 additional hour is allowed for machines equipped with E-stick or auxiliary lines. 2 additional hours is allowed for machines equipped with E-stick and auxiliary lines. Failure of the hose assembly is defined as exposure of the reinforcement wires in the hose due to interference with the swing casting.

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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 3*****
0-1000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-2000 hrs, 19-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 3.0-hour job for Group 3
Note: 1 additional hour is allowed for machines equipped with E-stick or auxiliary lines. 2 additional hours is allowed for machines equipped with E-stick and auxiliary lines. Failure of the hose assembly is defined as exposure of the reinforcement wires in the hose due to interference with the swing casting.

PARTS DISPOSITION

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

Rework Procedure

1) Remove all boom, bucket, stick, e-stick and auxiliary hoses from the control valve to their end points.
Note:
Removal of some of the bulkhead fittings will be necessary to remove the hose assemblies. Retain the bulkhead fittings for a later step.

2) Remove the connector assembly (141-8328) from the bucket rod end port of the bucket control valve.
Note:
This is the upper port on 420E and 430E, and the lower port on 416E.

3) Attach the connecter assembly (6V-8713 connector, 3D-2824 seal and 7J-9108 seal) to the bucket rod end port of the bucket control valve.

4) On 420E and 430E machines only, reorient the elbow fitting (8T-0120)located in the head end port of the stick cylinder to the position shown in image 1.4.1.
Note: The Boom cylinder rod end tube may need to be adjusted to prevent rubbing of the boom rod end hose coupling and the stick head end hose. Refer to image 1.4.2 for possible interference location and how to adjust if needed.

Image1.4.1

Image1.4.2

5) Locate the bulkhead plate on the boom. It is located under the stick cylinder. Refer to image 1.5.1 to locate the bulkhead plate.

Image1.5.1

6) Attach the fittings to the bulkhead plate as shown in image 1.6.1.
Note:
One of the fittings is new and some have been relocated. The new fitting is located in the Bucket rod end position and the part number is 268-1547. Also required is 6V-9170 nut, 6V-8398 seal and 7J-9108 seal.

Image1.6.1

7) Combine the hose assemblies in the tables below to create the lines groups.
Note:
A) They are different for each model.
B) The auxiliary hose assemblies do not need to be combined.
C) The lines groups are shown below (image 1.7.1). An example of the lines groups is shown in image 1.7.2 and 1.7.3.

Image1.7.1

Image1.7.2

Image1.7.3

8) Route the lines groups through the swing frame and connect to their respective valve ports (including auxiliary hose assemblies if equipped). Refer to image 1.8.2 for proper routing of the lines groups.
Note:
A) When connecting the lines groups to the valves, the hose assemblies with the clamped sleeve will need to be connected to the top port of the valve. (Image 1.8.1)
B) The opposite end of the lines groups will be connected in a later step.
C) The auxiliary lines are routed on top of the other implement lines groups in the swing frame.

Image1.8.1

Image1.8.2

9) Route and connect the hose assemblies shown in the chart below (image 1.9.1) to their respective cylinder ports or bulkhead connectors. Route the hose assemblies through the upper boom mounting block and tighten the mouting block bolts. Image 1.9.2 shows the correct routing for a 416E through the mounting blocks and image 1.9.3 shows the correct routing for a 420E or 430E.
Note:
All the connectors at the lower block should be aligned. The stick cylinder rod end hose has additional length. This extra length should be taken up in the area under the boom and stick cylinder mouting pin ("admiral's cap")on the boom.

Image1.9.1

Image1.9.2

Image1.9.3

10) Connect the lines groups from the swing frame with hoses assemblies routed through the upper boom mounting block. If equipped, attach the auxiliary lines to their tube as.

11) Route the hoses through the lower boom mounting block on the boom. Tighten the mouting block bolts.
Note:
A) The hoses should not cross coming from the boom and the extra hose length should be pushed into the swing frame.
B) Refer to image 1.9.2 for 416E routing through the block and refer to 1.9.3 for rounting on a 420E and 430E.

12) Tie strap the auxiliary lines together. Refer to image 1.12.1.