PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE LOWER FRAME ON CERTAIN M325C, M325CL, M325D AND M325DL MH EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE LOWER FRAME ON CERTAIN M325C, M325CL, M325D AND M325DL MH EXCAVATORS [REBE3205]

UNDERCARRIAGE

UNDERCARRIAGE GP

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE LOWER FRAME ON CERTAIN M325C, M325CL, M325D AND M325DL MH EXCAVATORS

REBE3205-01

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02Apr2008

(Revised 01May2008)

U-164

A-131

O-148

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE LOWER FRAME ON CERTAIN M325C, M325CL, M325D AND M325DL MH EXCAVATORS
4150		PI10669

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10669" 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 "PI10669" 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:	This Revised Service Letter replaces the 02Apr2008 Service Letter. Changes have been made to the Action Required and Rework Procedure to add details (reference to PI program number) in the way the DSN Service Request should be entered.

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PROBLEM

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The lower frame (top ring area) needs to be inspected every 1000 SMU on certain M325C, M325CL, M325D, and M325DL MH Excavators. Cracks can appear in the top ring of 238-0073 or 234-2240 Lower Frame. Cracks can initiate at the weld toe between ring and tower and can propagate to final failure. This may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
M325C MH	XJA00202-00292
M325D MH	EDF00221-00226, 229-232, 234-235, 240

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*****Group 2*****
M325C MH	PAN00242-00277, 279, 282-283, 285-343
M325D L MH	KAY00231-00233, 237, 239 KGG00211-00212

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1P3703	SEAL-RECTANGULAR - IF NEEDED
2	3D2824	SEAL-O-RING - IF NEEDED
5	3J1907	SEAL-O-RING - IF NEEDED
16	3K0360	SEAL-O-RING - IF NEEDED
8	4I6806	BOLT - IF NEEDED (FOR SWING BEARING)
2	4J0522	SEAL-O-RING - IF NEEDED
2	4J5267	SEAL-O-RING - IF NEEDED
2	5K9090	SEAL-O RING - IF NEEDED
42	6C9139	SPACER - IF NEEDED
8	6V7676	LOCKNUT - IF NEEDED
17	6V8397	SEAL-O-RING - IF NEEDED
30	6V8398	SEAL-O-RING-ORFS - IF NEEDED
5	6V9746	SEAL-O RING - IF NEEDED
1	7X7664	GREASE-MP - IF NEEDED
2	7Y0623	NUT-SELF LOCKING - IF NEEDED
2	8T6850	SEAL-O-RING - IF NEEDED
2	8T7876	SEAL-O-RING - IF NEEDED
12	9T2905	SPRING-BELLVILLE - IF NEEDED
1	0951608	SEAL-O-RING - IF NEEDED
25	1123928	BOLT - IF NEEDED (FOR SWING BEARING)
42	1123929	BOLT - IF NEEDED
16	1129145	LOCKNUT - IF NEEDED
14	1475112	BOLT-HEX HEAD - IF NEEDED (FOR SWING BEARING)
5	1853983	GASKET MAKER - IF NEEDED
120	2173403	SEAL-BULK - IF NEEDED
1	2342240	FRAME AS - IF NEEDED
16	2355626	LOCKNUT - IF NEEDED
39	2695454	SPACER - IF NEEDED (FOR SWING BEARING)
1	2845726	GEAR GP-BEARING - IF NEEDED (FOR SWING BEARING)
4	2898308	FILM-ARROW - IF NEEDED
1	3136594	FILM-WARN (EXIT) - IF NEEDED
1	3139685	FILM-WARN - IF NEEDED
*****Group 2*****
2	1P3703	SEAL-RECTANGULAR - IF NEEDED
2	3D2824	SEAL-O-RING - IF NEEDED
5	3J1907	SEAL-O-RING - IF NEEDED
15	3K0360	SEAL-O-RING - IF NEEDED
2	4J0522	SEAL-O-RING - IF NEEDED
2	4J5267	SEAL-O-RING - IF NEEDED
2	5K9090	SEAL-O RING - IF NEEDED
42	6C9139	SPACER - IF NEEDED
8	6V7676	LOCKNUT - IF NEEDED
12	6V8397	SEAL-O-RING - IF NEEDED
33	6V8398	SEAL-O-RING-ORFS - IF NEEDED
4	6V9746	SEAL-O RING - IF NEEDED
1	7X7664	GREASE-MP - IF NEEDED
2	7Y0623	NUT-SELF LOCKING - IF NEEDED
2	8T6850	SEAL-O-RING - IF NEEDED
2	8T7524	SEAL-O-RING-STOR - IF NEEDED
2	8T7876	SEAL-O-RING - IF NEEDED
12	9T2905	SPRING-BELLVILLE - IF NEEDED
1	0951608	SEAL-O-RING - IF NEEDED
25	1123928	BOLT - IF NEEDED (FOR SWING BEARING)
42	1123929	BOLT - IF NEEDED
16	1129145	LOCKNUT - IF NEEDED
14	1475112	BOLT-HEX HEAD - IF NEEDED (FOR SWING BEARING)
1	1738277	SEAL-O-RING - IF NEEDED
1	1776970	SEAL-O-RING - IF NEEDED
5	1853983	GASKET MAKER - IF NEEDED
120	2173403	SEAL-BULK - IF NEEDED
16	2355626	LOCKNUT - IF NEEDED
1	2380073	FRAME AS.-UNDCRG - IF NEEDED
39	2695454	SPACER - IF NEEDED (FOR SWING BEARING)
1	2845726	GEAR GP-BEARING - IF NEEDED (FOR SWING BEARING)
4	2898308	FILM-ARROW - IF NEEDED
8	3104096	BOLT-HEX HEAD - IF NEEDED (FOR SWING BEARING)
1	3136594	FILM-WARN (EXIT) - IF NEEDED
1	3139685	FILM-WARN - IF NEEDED

ACTION REQUIRED

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Inspect the machine in order to determine if the lower frame is a Fabricated Ring Frame or a Forged Ring Frame. Refer to Image 1. If the machine has a Forged Ring Frame, no further inspection is needed. Submit a SIMS ticket and enter that the machine is equipped with a "Forged Ring Frame" in the comment field. For fabricated ring frames, refer to the attached Rework Procedure for inspection details.

If a crack is found, remove the machine from service, and to help expedite the process, please be prepared to provide pictures and crack dimensions when contacting your local AVSpare Dealer Technical Communicator to submit a DSN (Dealer Solution Network) Service Request for further instructions. This Service Request must be submitted as a "High Priority" status and must reference the Service Letter "PI10669" in the 'Expectation Justification' field.
If no crack is found, the machine can be placed back into service. Schedule initial inspection as soon as possible and establish an inspection plan with the customer to have the frame inspected every 1000 SMU. Continue inspections every 1000 SMU until the frame is replaced. Submit the claim against this program for every subsequent inspection and replacement.

NOTE: Parts will not be supplied through the normal parts procurement process. The dealer Technical Coordinator (TC) needs to contact the DSN after the frame inspection has been completed and a crack has been found.

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Image1

Image2

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 5.0-hour job for Group 1
NOTE: Inspections must be conducted every 1000SMU. Each visit should be claimed against this service letter. NOTE: An additional 132 Hours will be allowed to replace the frame if recommended by DSN. Maximum $3500 are allowed to be claimed for a bridging machine (max $500 per day for max 7 days). Maximum $1000 are allowed to be claimed for machine transport to dealer branch and/or crane rental. NOTE: An additional 8 Hours will be allowed to replace the swing bearing if recommended by DSN.

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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 5.0-hour job for Group 2
NOTE: Inspections must be conducted every 1000SMU. Each visit should be claimed against this service letter. NOTE: An additional 132 Hours will be allowed to replace the frame if recommended by DSN. Maximum $3500 are allowed to be claimed for a bridging machine (max $500 per day for max 7 days). Maximum $1000 are allowed to be claimed for machine transport to dealer branch and/or crane rental. NOTE: An additional 8 Hours will be allowed to replace the swing bearing if recommended by DSN.

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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

SAFETY - Product Improvement Program For Performing Regular Inspections Of The Lower Frame Top Ring

MODELS INVOLVED - M325C, M325CL, M325D AND M325DL MH

Dear AVSpare Product Owner:

The lower frame needs to be inspected every 1,000 SMU on the products listed below. Cracks can appear in the top ring of the lower frame on the products listed below. This crack could propagate and final failure may result in machine separation and personal injury or death. You will not be charged for the service performed.
Machine on which inspection was not performed within last 1000SMU must be placed out of service until inspection is performed.

Contact your local AVSpare dealer immediately to schedule this service and plan for regular inspections. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 02Apr2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

AVSpare Inc.

Identification #(s)

Attached to 02Apr2008 Service Letter

Rework Procedure

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This Inspection program should be performed every 1,000 SMU. Please make arrangement with customer to avoid machine being operated if it has not been inspected within 1000SMU interval.

Perform penetrant test on the fabricated frame (tower to top ring area).
1. In the swing area, apply a cleaner to the surface test area and wipe off to clean. The test surface area should be free from any rust, scale, grease, paint, oily films, dirt,etc. These items can interfere with penetration.
2. Spray the penetrant to cover the test area.
3. Allow about twenty minutes before removing. Remove excess penetrant with cleaner/remover. Do not flush the surface with the cleaner/remover because this will impair sensitivity. Repear application of cleaner with additional wiping until residual surface pentrant has been removed.
4. Apply an even, thin film layer of developer over the area being inspected. Allow the developer film to dry completely before making observation for presence of surface discontinuities. A recommended developing time is 5 to 15 minutes.
5. The developer will act to draw the entrapped penetrant out of the discontinuity. A color change of deveoper will be an indication that there is a possible surface discontinuity present.
6. Clean and repaint surface.
For additional references, please refer to ASTM E1220-05, ISO 3452, EN 571 or similar standard.

If a crack is found, remove the machine from service, and to help expedite the process, please be prepared to provide pictures and crack dimensions when contacting your local AVSpare Dealer Technical Communicator to submit a DSN (Dealer Solution Network) Service Request. This Service Request must be submitted as a "High Priority" status and must reference the Service Letter "PI10669" in the 'Expectation Justification' field.