PRODUCT SUPPORT PROGRAM FOR REWORKING THE IDLER GROUP SUPPORT ON CERTAIN 385B, 385C AND 5090B EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE IDLER GROUP SUPPORT ON CERTAIN 385B, 385C AND 5090B EXCAVATORS [REBE2933]

UNDERCARRIAGE

TRACK ADJUSTER & RECOIL GP

PRODUCT SUPPORT PROGRAM FOR REWORKING THE IDLER GROUP SUPPORT ON CERTAIN 385B, 385C AND 5090B EXCAVATORS

REBE2933-01

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11Feb2009

(Revised 19Jun2009)

U-54

A-47

D-44

O-44

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE IDLER GROUP SUPPORT ON CERTAIN 385B, 385C AND 5090B EXCAVATORS
4158		PS42878

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42878" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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NOTE:	This Revised Service Letter replaces the 11Feb2009 Service Letter. Changes have been made to the Title, Affected Product, and Parts Needed.

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TERMINATION DATE

28Feb2011

PROBLEM

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The idler support may fail on certain 385B, 385C and 5090B Excavators that are operating in severe applications, like traveling at rock fields.
Rocks may get caught between the sprocket or idler and track link causing tension in the track. Large enough rocks can use up the spring stroke, and the rod pipe and the support yoke can contact each other.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
385C	JCM00175-00183 KBC00201-00240 KKK00123-00207
385C FS	EAM00264-00289 MMA00245-00259 T2F00181-00188
385C L	EDA00189-00499 KGB00275-00444 SBE00168-00365 T2E00291-00341
385C L MH	WAW00211-00220

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*****Group 2*****
385B	ANS00227-00346 BKF00206-00208 BKX00124, 127, 141, 146, 166, 178 BLY00152-00168 CLS00206-00277 RCD00152-00276
385B L	FDL00151-00283 MYA00291-00292
5090B	CLD00312-00350 SJY00106-00107

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	8T6594	BOLT-SOCKET HEAD
2	1686740	WASHER
2	1686741	NUT
2	1686742	PLATE
16	1740221	BOLT-TRACK
16	1740222	NUT-TRACK
2	2487161	ROD
2	2487163	SPRING
2	2979120	SUPPORT AS
2	2979121	SUPPORT
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
4	8T6594	BOLT-SOCKET HEAD
2	1686740	WASHER
2	1686741	NUT
2	1686742	PLATE
16	1740221	BOLT-TRACK
16	1740222	NUT-TRACK
2	2487161	ROD
2	2487163	SPRING
2	2979120	SUPPORT AS
2	2979121	SUPPORT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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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%
*****Group 1*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 37-48 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 34.0-hour job for Group 1

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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%
*****Group 2*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-8000 hrs, 37-48 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 34.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Image1.1.1

A) Recoil Spring - Assemble

1) Assemble new Recoil-Spring (248-7308) Spring Group-Recoil (3). Assemble the recoil spring.

2) Refer to Disassembly and Assembly Manual, RENR5407, for details. (SMCS-4158-016)

3) The weight of new recoil spring assembly (3) is approximately 610kg (1345 lb).

4) The assembled length must be 1194.0 +/- 1.0 mm (47.00 +/-0.04 inch).

Image1.2.1

B) Front Idler and Recoil Spring - Remove

1) Disassemble the recoil spring. Refer to Disassembly and Assembly Manual, RENR5407, (SMCS-4158-011 , 4159-011) for details. All of the details are the same with the following exceptions:
a) The weight of the unit is approximately 1019 kg (2247 lb).
b) The weight of recoil spring assembly (3) is approximately 592 kg (1305 lb).
2) The weight of front idler (1) is approximately 413 kg (911 lb).

Image1.3.1

C) Track Roller Frame Rework Procedure for New Recoil System

1) Use a grinder and rework the right and left track frame as shown in Image 1.4.1. (Idler wheel interference prevention)

Image1.4.1

2) The detail process dimensions are shown in Image 1.5.1.

Image1.5.1

3) Each process sections are shown in Image 1.6.1.

Image1.6.1

D) Front Idler and Recoil Spring-Install

1) Assemble and install the recoil spring and front idler. Refer to Disassembly and Assembly Manual, RENR5407, (SMCS-4158-012,4159-012), for details. All of the details are the same with the following exceptions:
a) The weight of front idler (1) is approximately 413 kg (911 lb).
b) The weight of recoil spring assembly (3) is approximately 610kg (1345 lb)
c) The weight of the unit is approximately 1040 kg (2293 lb).