PRODUCT SUPPORT PROGRAM TO ADJUST AND PROTECT THE SIDESHIFT AND BACKHOE HOSES ON CERTAIN 428E NARROW FRAME BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM TO ADJUST AND PROTECT THE SIDESHIFT AND BACKHOE HOSES ON CERTAIN 428E NARROW FRAME BACKHOE LOADERS [REBE1783]

HYDRAULIC SYSTEM

LINES GP-BOOM

PRODUCT SUPPORT PROGRAM TO ADJUST AND PROTECT THE SIDESHIFT AND BACKHOE HOSES ON CERTAIN 428E NARROW FRAME BACKHOE LOADERS

REBE1783-00

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04May2007

D-139

O-150

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*Before/After*	PRODUCT SUPPORT PROGRAM TO ADJUST AND PROTECT THE SIDESHIFT AND BACKHOE HOSES ON CERTAIN 428E NARROW FRAME BACKHOE LOADERS
5057		PS42396

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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 "PS42396" 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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TERMINATION DATE

31May2008

PROBLEM

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The sideshift hoses may be twisted and require rerouting on certain 428E Narrow Frame Backhoe Loaders. There may also be some rubbing between the hoses which route through the swing casting.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
428E	SNL00188, 195, 281, 303, 307, 310-316, 346, 406-407, 409, 413-415, 429-430, 445, 509, 513, 519-521, 523, 549, 551, 626, 628-629, 674, 679-681, 695, 701-703, 731, 801-802, 804-805, 821-822, 825, 958, 983, 1027-1028, 1086-1090, 1092, 1097-1098, 1123-1151, 1153-1166, 1168, 1170-1173, 1175-1176, 1178-1179, 1185, 1193, 1206

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*****Group 2*****
428E	SNL00193, 196, 291, 299-300, 317, 340-342, 555-556, 723, 735, 737, 1095-1096, 1152, 1196, 1198

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*******Group 3*******

428E

SNL00168, 176, 178, 182, 184-185, 187, 191, 202-203, 225-228, 304-306, 308-309, 318-328, 337-339, 343, 347, 354-357, 359, 396, 402-404, 410-412, 423, 428, 439, 441-443, 490, 492, 494-500, 503-508, 529-531, 559-560, 563, 582-584, 586-587, 589, 591, 600, 602, 604-605, 610, 663, 666, 668, 672-673, 677-678, 707, 716-717, 719, 722, 725-726, 730, 755-759, 762, 764-766, 768, 770-773, 786, 790, 792-793, 797, 799-800, 803, 811, 820, 834, 880-883, 891, 894, 930, 984-985, 987-989, 991, 1065, 1167, 1169, 1209-1210, 1228-1229

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
20	3S2093	STRAP-CABLE
1	6R2935	HOSE AS
2	6V8398	SEAL-O-RING
4	7J9108	SEAL-O-RING
106	1602244	SLEEVE-ABRASION
232	1602246	SLEEVE-ABRASION
6	1638811	CLAMP
1	3031531	HOSE AS.
1	3031532	HOSE AS.
*****Group 2*****
22	3S2093	STRAP-CABLE
1	6R2935	HOSE AS
2	6V8398	SEAL-O-RING
5	7J9108	SEAL-O-RING
106	1602244	SLEEVE-ABRASION
285	1602246	SLEEVE-ABRASION
7	1638811	CLAMP
1	3031531	HOSE AS.
1	3031532	HOSE AS.
1	3031542	HOSE AS.
*****Group 3*****
24	3S2093	STRAP-CABLE
1	6R2935	HOSE AS
2	6V8398	SEAL-O-RING
6	7J9108	SEAL-O-RING
106	1602244	SLEEVE-ABRASION
338	1602246	SLEEVE-ABRASION
8	1638811	CLAMP
1	3031531	HOSE AS.
1	3031532	HOSE AS.
2	3031542	HOSE AS.

ACTION REQUIRED

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Follow the attached rework procedure to re-align the sideshift hoses and provide protection to the hoses routed through the swing casting.

Some machines may have had the hoses reworked already at the factory. These can be identified by looking at the hoses in the boom foot: machines already reworked will have sleeving over these hoses. In these cases, it may be necessary to dress the top doubler plates, as indicated in the rework procedure below. Fully sideshift the carriage to check for any foul conditions and rework as indicated.

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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*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 1

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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*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 2

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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*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 3

PARTS DISPOSITION

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

Rework Procedure

RE-ALIGN SIDESHIFT LINES

1.Sideshift the slide frame to the RHS of the machine. Swing the hoe to the central position, then extend the boom and stick fully and place the bucket on the floor. Turn off the engine.

2.Operate the hoe control levers (including the auxiliary control pedal - if fitted) to relieve pressure in the hydraulic lines.

3.Loosen the sideshift hose clamps, as shown in image 1.1.1. There are three bolts per clamp.

Image1.1.1

4.Disconnect the hoses which route through the swing casting at the bulkhead fittings, as shown in image 1.2.1. Plug the open ends of the disconnected hoses to prevent dirt ingress and to aid fitting the protective sleeves.

5.Once all the hoses have been disconnected, loosen the bulkhead fitting lock nuts. This will allow any twisted hoses to find their natural route. Check the sideshift hoses and clamps for damage and replace as necessary. Take care when removing any hoses from the bulkhead clamps as they may be under tension and spring out unexpectedly. Wear appropriate eye protection.

Image1.2.1

6.Check the configuration of the machine and replace the LHS sideshift hoses as shown in the table below (image 1.3.1). Both bucket cylinder supply hoses need to be replaced. The auxiliary supply hoses and e-stick supply hoses (if installed) also need to be replaced. See image 1.3.2.

Image1.3.1

Image1.3.2

7.Additional protection needs to be added to the top sideshift hose on each side (E-stick line on LHS, Boom cyl line on RHS). Disconnect the hose from the bulkhead bracket and add 250mm of 160-2246 sleeve to the hose. Secure at each end with two 3S-2093 tie straps, as shown in image 1.3.1. Reconnect the hose loosly to the bulkhead bracket.

8.Check the alignment of the hoses. Some hoses will not spring into place and will need to be turned manually to run parallel to the other hoses.

9.With the hoses realigned parallel to each other, tighten the bulkhead lock nuts. Use a back-up spanner to hold the hose in position and prevent it twisting during tightening. Tighten the 1-1/4" locknuts to 100Nm and the 1-1/8" locknuts to 75Nm. It is important to use these torque figures as this will prevent the sideshift hoses twisted when the backhoe hoses are re-connected.

10.When all of the bulkhead fittings have been tightened, reposition the sideshift lines clamps as shown in image 1.4.2. The measurements are taken from the back of the bulkhead fitting mounting bracket and are measured along the length of the hoses.

11. Adjust the swing cylinder supply hose so that there is 500mm of hose between the last sideshift clamp and the connection with the swing cylinder (image 1.4.3). Pull the hose through the sideshift clamps as required.

Image1.4.1

Image1.4.2

Image1.4.3

ADDING PROTECTION TO HOSES THROUGH SWING CASTING

12.Check the disconnected backhoe hoses for damage along the route through the swing casting and boom foot. Pay particular attention to the area around the boom foot pins. Replace any damaged hoses.

13.Check the machine configuration and use the table below to determine what type and how much sleeving to use.

Image1.5.1

14.Pull the sleeve over the disconnected end and along the hose. Secure the sleeve to the hose coupling with the 163-8811 clamp. See images 1.6.1, 1.6.2 & 1.6.3 At the other end, secure the sleeve to the hose with 2 x 3S-2093 ties.

15.Reconnect the hoses to the bulkhead fittings. Use new o-rings for each connection.

Image1.6.1

Image1.6.2

Image1.6.3

DRESS DOUBLER PLATES

16.To further prevent the hoses rubbing, the doubler plate between the stabiliser leg and the top H-frame rail needs to be dressed. Grind a 5mm radius onto the inside edge of the plate, as shown in images 1.7.1 & 1.7.2. Complete by repainting the dressed area.

17.Start the machine and operate the hoe, checking for leaks. Once complete, sideshift the slide frame to the LHS of the machine.

Image1.7.1

Image1.7.2

18.Repeat steps 2-5 for the RHS hoses.

19.Replace the lower swing cylinder supply hose, 249-2975 (see image 1.8.1), with new hose 6R-2935. Follow the same routing as the 249-2975 hose to ensure that there is no contact between the hose and the edge of the slide frame during operation. As in step 11, ensure that there is 500mm of hose between the last sideshift clamp and the connection to the swing cylinder (image 1.4.3).

Image1.8.1

20.Complete the reworks of the RHS hoses by repeating steps 7-17.

21. Fully sideshift the machine several times to check for any interference of the hoses during operation. Pay particular attention when the backhoe is fully sideshifted to the left and right. Check hose clearance behind the slide frame and above the swing cylinders. Ensure that there are no hoses rubbing on the swing cylinders when the backhoe is swung from side to side.