</font><font color="blue" class="small">( Dealer says the Boom locking pin is for safety. )</font>
You betcha.
</font><font color="blue" class="small">( He said the boom pin repair is not a warranty item Should the pin fallout or shear if you accidentally push "down" boom when LOCKED????? )</font>
If it came out as a result of the boom being pushed down, no I don't think it would (or should be) a warranty item. The lock pin is designed to support the weight of the boom, dipperstick, cylinders, and bucket when the 'hoe is not being used. The weight of those items is probably not more than 800 lbs. - the boom cylinder however is capable of generating a downforce of over 6000 lbs. The pin is not designed to handle that kind of force. If the pin didn't come out/shear off, it's possible that there would be other more expensive to repair damage that could occur.
</font><font color="blue" class="small">( Anybody else have this happen?? )</font>
I think there was a thread recently where the boom lock pin on a BL4690 'hoe (could have been a BH90) came out - as I recall the pin was welded on one side only (outside) of the plate it was in. I believe when the person repaired it they welded both sides.