CLUTCH & BRAKE GP-STEERING 9U9082 - Caterpillar

This is a 12.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE STANDARD STICK
MODELS INVOLVED - 432E AND 434E BACKHOE LOADERS
Dear Caterpillar Product Owner:
New reinforcement plates need to be installed on the products listed below. If the reinforcement plates are not installed, the standard stick may fail in the general area of the stick cylinder 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 Caterpillar 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 26Oct2006 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.
Caterpillar Inc.
Identification #(s)
Attached to 26Oct2006 Service Letter
Rework Procedure
"Procedure for adding reinforcement plates on the standard stick for the 420E backhoe loader"
1.Remove the stick from the machine. Refer to Disassembly and Assembly 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 and install the reinforcement plates (if not already installed).
Image1.1.1
Image1.1.2
Remove 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 using the dimensions below and mark the areas on the stick where the triangular outer plates will be welded.
Image1.3.1
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 control 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.Protect the pin bores from weld spatter. Weld the saddle plate according to the illustrations shown below.
Image1.7.1
Image1.7.2
Image1.7.3
Welding the Outer Plates
12.Position the outer plates according the dimensions shown below. (Dimensions are typical for both sides.)
Image1.8.1
13.Protect the pin bores from weld spatter. Tack and weld the outer plates. Use the weld callouts shown in the above illustration.
Image1.9.1
14.Repaint the stick
15.Install the stick back onto the machine. Refer to Disassembly and Assembly RENR6485 ?Stick ? Remove and Install?.