PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOMS AND GREASE LINES ON CERTAIN M325C AND M325D EXCAVATORS THAT ARE EQUIPPED FOR MATERIAL HANDLING APPLICATION Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOMS AND GREASE LINES ON CERTAIN M325C AND M325D EXCAVATORS THAT ARE EQUIPPED FOR MATERIAL HANDLING APPLICATION [REBE1089]

IMPLEMENTS

LINES GP-GREASE

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOMS AND GREASE LINES ON CERTAIN M325C AND M325D EXCAVATORS THAT ARE EQUIPPED FOR MATERIAL HANDLING APPLICATION

REBE1089-00

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02Nov2006

U-711

A-683

D-668

O-693

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOMS AND GREASE LINES ON CERTAIN M325C AND M325D EXCAVATORS THAT ARE EQUIPPED FOR MATERIAL HANDLING APPLIAVSION
7510		PI31177

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31177" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31177" as the Part Number, "7751" as the Group Number, "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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COMPLETION DATE	TERMINATION DATE
31May2007	30Nov2007

PROBLEM

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The 2 157-4604 Manifolds for the grease lines need to be removed on certain M325C and M325D Excavators that are equipped for material handling application. The existing boom assemblies can fail due to these welded manifolds. New bolted manifolds are replacing the welded manifolds in order to improve the structural durability of the booms.

AFFECTED PRODUCT

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Model	Identification Number
M325C MH	PAN00243-00257, 259-275, 278-290, 295, 297-304, 307-312, 315-334, 336, 338-343 XJA00203-00292
M325D L MH	KAY00231-00232 KGG00211
M325D MH	EDF00221-00223, 230, 232

PARTS NEEDED

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Qty	Part Number	Description
1	2920938	SUPPORT AS.
4	7Y4531	CLAMP-HALF
4	8T4183	BOLT
8	8T4223	WASHER-HARD
4	8T4244	NUT

ACTION REQUIRED

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See attached rework procedure

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OWNER NOTIFIAVSION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 8.0-hour job

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOMS AND GREASE LINES

MODELS INVOLVED - M325C AND M325D EXCAVATORS THAT ARE EQUIPPED FOR MATERIAL HANDLING APPLIAVSION

Dear AVSpare Product Owner:

The 2 157-4604 Manifolds for the grease lines need to be removed on the products listed below. The existing boom assemblies can fail due to these welded manifolds. New bolted manifolds are replacing the welded manifolds in order to improve the structural durability of the booms. If this is not done, the boom may crack prematuraly. You will not be charged for the service performed.

Contact your local AVSpare 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 02Nov2006 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

AVSpare Inc.

Identification #(s)

Attached to 02Nov2006 Service Letter

Rework Procedure

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Remove the two manifolds for the greasing lines at boom foot:
Grind the welds between manifolds and side plate smoothly. Avoid any undercut into the side plate - see Image1.1.1

Image1.1.1

Check the side plate to see if it is cracked:
If no crack is found, then go to next paragraph.

If the side plate is cracked, please take pictures and submit detailed request for advice on repair possibility to the following AVSpare Service Engineer:
Christian Muehle
phone: #32 (0)71 25 2559
Email: Muhle_Christian@cat.com
In case of agreement with AVSpare of small crack like seen in the attached picture (Image 1.2.1), then repair crack by doing the following chamfer - see Image 1.2.2
Cut 20mm away each side of the crack.
Gap must be minimum and will strongly affect the quality of the weld - See Image 1.2.2
Weld a first pass very carefully to avoid weld flow inside the stick: see Image 1.2.3
Finish the weld and grind it so that the weld is perfectly flat with the surface of the plate - See Image 1.2.4

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

New support assembly:
Assemble support 292-0938 on top side Tube with clamp half 7Y4531(qty: 4), bolt 8T4183 (qty: 4), washer hard 8T4223 (qty: 8) and nut 8T4244 (qty: 4)
See Image 1.3.1

Respect the distance between support and Tube extremity of 251 +- 5 mm
See Image 1.3.2