SHAFT 0546739 - Caterpillar

August 20, 2001
(Revised December 2001)
AU-242
S-192
H-148
O-166
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPAIRINGMAIN FRAME CRACKS ADJACENT TO FRONT AXLE MOUNT ON CERTAIN 416C, 426C, 436C,428C AND 438C BACKHOE LOADERS
7054 PS50123
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50123" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe August 20, 2001 Service Letter. Changes have been made to the MailCodes.TERMINATION DATE
August 31, 2003PROBLEM
The main frame cracks adjacent to front axle mounton certain 416C, 426C, 436C, 428C and 438C Backhoe Loaders. Incorrect axlepivot shimming and / or severe front loader application can cause cracksto initiate to the front and to the rear of the front axle mount sub-frameweld interface.AFFECTED PRODUCT
416C 5YN1-16922
1XR1-2259426C 7WN1-1107
1ZR1-1014
1ER1-902436C 9JN1-1054
2BR1-1002
1RR1-1101428C 2CR1-21543
8RN1-5226438C 2DR1-3700
1TR1-2010
9KN1-1411
1JR1-1156PARTS NEEDED
2 - 1K7082 Washer
2 - 9R9702 Washer
2 - 1658996 Washer - Thrust
1 - 1925375 Plate
1 - 1925376 Plate
2 - 1925377 Plate
2 - 1925378 PlateACTION REQUIRED
See the attached rework procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-6000 / 0-48 mo 100 % 20 0 0 0 0
This is a 20-hour job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Front Axle shimmingCheck the clearance between the Front axleand the Front axle mount, if the end float of the axle is more than 0.8mm re-shimming should be carried out, using the relevant shims listed inthe Service letter.Weld procedure
At all the cracks, grind a "V" into the crack6 mm deep on the outside and 8 mm on the inside, weld and grind flush.
Clamp on the outside plate and using a 6-mm fillet,weld from the top left corner in a clockwise direction to the bottom rightcorner.
Along the bottom edge use a bevel weld makingsure that there is good penetration into the existing weld, the new plateand the frame.
Note: Do not weld the vertical edge nextto the axle stop.
Grind off the welded boss near too the front axlesupport back plate on the left-hand side of the machine and clamp the frontpart of the inner plate to the frame. Using a 6-mm fillet weld from thebottom right corner in a counter-clockwise direction to the top corner.
Go back to the start point of the last weld andadd a bevel weld from here leftwards along the next 3 edges, making surethat there is good penetration into the existing weld, the new plate andthe frame.
Unclamp the plate and re-clamp at the rear endof the plate. The plate MUST be kept tight against the frame andshould now be bent slightly.
Continue the 6-mm fillet weld from the top cornerto the bottom left corner.
Continue the bevel weld over & around therear axle support plate.
On the