PRODUCT SUPPORT PROGRAM FOR REWORKING BOOM FOOT CRACKING ON CERTAIN 315B AND 315C EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING BOOM FOOT CRACKING ON CERTAIN 315B AND 315C EXCAVATORS [REBE1664]

IMPLEMENTS

BOOM GP

PRODUCT SUPPORT PROGRAM FOR REWORKING BOOM FOOT CRACKING ON CERTAIN 315B AND 315C EXCAVATORS

REBE1664-00

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20Mar2007

U-106

A-90

D-90

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING BOOM FOOT CRACKING ON CERTAIN 315B AND 315C EXCAVATORS
6501		PS51279

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51279" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31Mar2009

PROBLEM

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The existing butt welding joint of top plate, the inserted baffle welding joint, or the lower plate fillet welding joint for the boom foot can cause a crack on certain 315B and 315C Excavators.

AFFECTED PRODUCT

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Model	Identification Number
315B	1SW00188-00191, 195-276 3AW00312-00410, 412-419, 421-432, 437, 439, 442, 446, 451-455, 458-459, 461, 463, 465, 471-472, 476, 486, 493-495, 499-502, 505-510, 512-513, 517-522, 524-530, 532-534, 536-542, 544-547, 549, 551-1972, 1974-2018, 2022-2036, 2038-2046, 2048-2055, 2057-2061, 2065, 2069-2074, 2076-2080, 2082-2088, 2090-2125, 2139-2158, 2160-2164, 2166-2171, 2175, 2184-2204, 2206, 2208-2213, 2222-2225, 2228-2253, 2258-2259, 2261-2269, 2271-2275, 2283, 2285-2290, 2292-2295, 2297, 2300-2301, 2303-2304, 2309-2327, 2330-2342, 2344-2345, 2347-2348, 2350-2352, 2354, 2357, 2359-2365, 2370-2378, 2381-2408, 2412-2428, 2431, 2433-2434, 2436, 2439-2440, 2442-2446, 2448-2450, 2453-2480, 2482-2509, 2512-2626, 50312 7RZ00283-00290
315C	AKE00191-00219 CFB00111-00145
315CL	CFT00179-00232, 234-238, 240-242, 244-484, 486-1021, 1023-1369 CJC00101-00122, 124-208, 210-412, 414-889, 891-921, 923-1198, 1200-1439, 1441-1445, 1447-1483, 1485-1539, 1541-1858, 1860-1885, 1887-2221, 2223-3389, 3391-3868, 3870-4014, 4016-4166, 4168-4176, 4178-4217, 4219-4225, 4227-4230, 4232-4467, 4469-4476

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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If the existing butt weld joint of top plate ('A' point of image 1), inserted baffle weld joint ('B' point of image 1), or lower plate fillet weld joint ('C' point of image 1) of the boom foot has cracked in the field the crack needs to be repaired. See the attached procedure to repair boom foot.

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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%
0-5000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
5001-8000 hrs, 61-96 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 29.0-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.

Rework Procedure

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Part 1. Remove former lower plates

1). Remove lower side fillet weld of boom foot by using gauging along the welded line.
Remove V-groove weld of lower plate side butt weld joint of boom foot.
Remove rear boom lower plate from by gauging.
Refer to image 1.1.1 & 1.1.2 (Note: Smooth all repaired weld joint and surface by grinding.)

Image1.1.1

Image1.1.2

Image 1.1.1 & 1.1.2 Removal procedure for these boom foot area

2). And also, cut center area of baffle plate based on image 1.1.2 by using gas
burner. Finish surface of cutting area of baffle plate smoothly by grinding. Finish fillet weld between remaining baffle plate and each plate smoothly by grinding.
Image 1.2.1

Image1.2.1

Image 1.2.1 Finishing fillet weld joint

3). Finish surface of all areas smoothly by grinding. Remove inside tack welds by gauging.

Part 2. Prepare reinforcement plate

1). Fabricate (1)to (7) reinforcement plate ( Mild steel) based on image 1.3.1 & 1.3.2

Image1.3.1

Image1.3.2

Image 1.3.1.& 1.3.2 Fabricate reinforcement plates

Part 3. Install reinforcement plate

1). Install four reinforcement plate (1) to (4) to top butt welding joint of Section 2-2 in image 1.4.1 at boom foot area And also install reinforcement (2) to bottom side and reinforcement (3) & (4) to both sides.
The top reinforcement (1) should be covered rear area top butt weld joint.

2). Weld reinforcement plates to top and bottom first, then weld reinforcement to both side.

3). Weld around all 4 reinforcement plates.
Refer to image 1.4.1 & 1.4.2 (Note: Smooth all repaired weld joint and surface by grinding)

Image1.4.1

Image1.4.2

Illustration 1.4.1. & 1.4.2 Procedure to install reinforcement

Part 4. Install new baffle plate

1). Install new baffle plate (5) to reinforcement plate welding point.
2). Weld all around of new baffle plate (5).
Refer to image 1.5.1 & 1.5.2.
(Note 1: If not using reinforcement plates, use same procedure, but ignore reinforcement plate graphics)
(Note 2: Smooth all repaired weld joint and surface by grind)

Image1.5.1

Image1.5.2

Image 1.5.1 & 1.5.2 Install new baffle plate

Part 5. Install new lower plate

1). Install backup strip (7) at rear bottom butt welding joint.
2). Install new rear bottom plate (6) which is increased thickness t8mm to 12mm.
3). Weld fillet weld joint and butt weld joint all around new rear bottom plate (6) Refer to illustration 1.6.1 & 1.6.2
(Note: Smooth all repaired weld joint and surface by grinding)