PRODUCT IMPROVEMENT PROGRAM FOR REMOVING MACHINES FROM SERVICE AND INSPECTING/REPLACING CYLINDERS ON CERTAIN 320D, 321D, 324D, 325D, AND 328D EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REMOVING MACHINES FROM SERVICE AND INSPECTING/REPLACING CYLINDERS ON CERTAIN 320D, 321D, 324D, 325D, AND 328D EXCAVATORS [REBE3469]

HYDRAULIC SYSTEM

CYLINDER GP

PRODUCT IMPROVEMENT PROGRAM FOR REMOVING MACHINES FROM SERVICE AND INSPECTING/REPLACING CYLINDERS ON CERTAIN 320D, 321D, 324D, 325D, AND 328D EXCAVATORS

REBE3469-00

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20Mar2008

U-145

A-113

D-107

O-129

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Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REMOVING MACHINES FROM SERVICE AND INSPECTING/REPLACING CYLINDERS ON CERTAIN 320D, 321D, 324D, 325D, AND 328D EXCAVATORS
7562		PI10667

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10667" 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 "PI10667" 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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PROBLEM

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The hydraulic cylinder rod may separate from the rod eye on certain 320D, 321D, 324D, 325D,and 328D Excavator boom, stick, and bucket cylinders. This may happen unexpectedly at any time during machine operation and presents a risk of personal injury or death. This problem affects 320D and 321D stick cylinders, and affects 324D, 325D, and 328D boom, stick, and bucket cylinders. Affected cylinders need to be ultrasonically tested (U/T) for a possible weld defect or replaced as described in the "Action Required" below.

AFFECTED PRODUCT

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Model	Identification Number
320D	BZP00384-00405 FAL00566, 733, 735-745, 748, 750-752, 756-805, 807-816, 818-841, 843-848, 850-879, 883, 886-889, 892-895, 897-898, 901-902, 904-906, 908-909, 911-914, 917-919, 923, 926-931, 933, 935-938, 941-946, 948, 952-962, 992, 995-996, 1002-1006, 1010-1019, 1022-1029, 1032 JFZ00793, 808-983, 987-988, 990-1047, 1051-1054, 1056-1061, 1064-1065, 1261-1279, 1281-1328, 1331-1405 KGF01073, 1075-1077, 1080-1085, 1087-1139, 1141-1143, 1145-1166, 1168-1171, 1173-1176, 1178-1182, 1184-1187, 1191-1219, 1222, 1224-1225, 1227-1230, 1233, 1235-1240, 1242, 1244, 1246-1253, 1255-1257, 1259-1260, 1262, 1267-1274, 1276-1297, 1299-1304, 1306-1309, 1311-1323, 1325-1346, 1348-1374, 1376-1401, 1403-1405, 1409-1412, 1418-1422, 1424, 1432-1434, 1437-1446, 1449-1454, 1458-1460, 1463, 1465, 1469, 1475, 1480, 1483, 1485-1489, 1492, 1498-1499, 1501, 1503-1506, 1508-1513, 1515-1517, 1519-1524, 1528-1544, 1546-1547, 1558, 1568 PHX01064, 1067, 1214, 1265, 1287-1289, 1291-1306, 1309, 1311-1317, 1319-1322, 1325, 1330-1366, 1368-1409, 1411-1416, 1418-1438, 1440-1461, 1463-1467, 1472-1493, 1498
320D L	A8F00560 MGG00411, 416-468
320D LN	WBN00163-00188, 191-196, 200-215, 217-222, 224-235
320D LRR	TAE00106 XCK00180-00196, 198-213, 219-220, 222, 224-226 ZGB00153-00156
320D RR	YDS00162
321D LCR	MDT00174, 176-177, 179-182, 184, 186 NAS00167-00170, 174, 178 PBD00157-00158, 160-162, 164-166
324D	CJX00285-00286, 288-294, 296-297, 300
324D L	DFP00326-00336, 338-339, 342-345
325D	DBH00333-00375 KDG00209-00212 SCR00755, 758-759, 761-772, 775-776, 778-783, 785, 787, 793-794, 797-798, 800, 802-805
328D	GTN00283, 296-311, 314-318 MKR00208-00210

PARTS NEEDED

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Qty	Part Number	Description
1	2254584	CYL GP-SEAL& (If Needed - See Action Required)
1	2254588	CYL GP-SEAL& (If Needed - See Action Required)
1	2254591	CYL GP-SEAL& (If Needed - See Action Required)
1	2254595	CYL GP-SEAL& (If Needed - See Action Required)
1	2254597	CYL GP-SEAL& (If Needed - See Action Required)
1	2254599	CYL GP-SEAL& (If Needed - See Action Required)
1	2426734	CYL GP-SEAL& (If Needed - See Action Required)
1	2426744	CYL GP-SEAL& (If Needed - See Action Required)
1	2426748	CYL GP-SEAL& (If Needed - See Action Required)
1	2426763	CYL GP-SEAL& (If Needed - See Action Required)
1	2426858	CYL GP-SEAL& (If Needed - See Action Required)
1	2426860	CYL GP-SEAL& (If Needed - See Action Required)
1	2426862	CYL GP-SEAL& (If Needed - See Action Required)
1	2426867	CYL GP-SEAL& (If Needed - See Action Required)
1	2426869	CYL GP-SEAL& (If Needed - See Action Required)
1	2590778	CYL GP-SEAL& (If Needed - See Action Required)
1	2667935	CYL GP-SEAL& (If Needed - See Action Required)
1	2667974	CYL GP-SEAL& (If Needed - See Action Required)
1	2667988	CYL GP-SEAL& (If Needed - See Action Required)
1	2667990	CYL GP-SEAL& (If Needed - See Action Required)
1	2667992	CYL GP-SEAL& (If Needed - See Action Required)
1	2959673	CYL GP-SEAL& (If Needed - See Action Required)
Due to world wide parts constraint, all of the cylinders listed are on freeze. Orders will be prioritized and released as quickly as possible by World Wide Excavator Product Support.

ACTION REQUIRED

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****Parts Stock ****

Determine if any of the cylinders listed above in the Parts Needed table are in dealer parts stock. If so, the cylinder date code needs to be inspected. Refer to Image 1 (photograph of actual cylinder part number and date code) and Image 2 (how to read the photographed information) below to determine the cylinder date code. If the date code is after 01 Nov 2007 and before 19 Jan 2008, these cylinders need to be removed from stock and not used. Likewise, if rod assemblies identified by the part numbers referenced in the Image 1 (table of models - part numbers - applications shown below the "Affected Model" information) are found in dealer parts stock, follow the same procedure as for cylinders. Refer to Parts Stock - Parts Disposition below for specific instructions.

Image1

Image2

****Affected Product****

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Please read and understand the following instructions thoroughly before proceeding with any action!

Important: Some machines in the Affected Serial Number list may have already had the corrective action of this Safety Product Improvement Program performed by AVSpare. In these cases, SIMS entries have already been entered and are identified with the number of this Safety Product Improvement Program in the "Part Causing Failure" field, Description Code 56, Group Number 7751, and referencing Dealer Code Z800 (AVSpare). Before performing this Service Letter on any affected serial number, please check in SIMSi to see if an entry for that serial number exists. If so, update that SIMSi record with your own dealer code. No further rework action is required for that serial number. If your investigation reveals no entry has been made for that affected serial number, proceed to further instructions below.

1.) Immediately remove all machines from service that are listed in the Affected Serial Number list.

All affected machines must be tagged with a "DANGER DO NOT OPERATE" tag. The tag, SEHS7332, is available either through the Parts Distribution System, or through the Media Logistics Ordering System. The master electrical disconnect switch should be turned to the OFF position. The affected machines are to remain out of service until all affected cylinders are inspected and/or replaced.

2.) One of two possible corrective actions below must be applied to complete this Service Letter:

A.) Ultrasonic Testing (U/T) of suspect cylinders;
OR
B.) Preventative replacement of suspect cylinders.

Suspect cylinder part numbers are matched with models and machine function in Image 1 (table of models - part numbers - applications) below.

Option A.) Ultrasonic Testing of suspect cylinders:

AVSpare has deployed U/T teams to inspect suspect cylinders on affected machines grouped together in greater numbers, and where inspection is preferable. The schedules of these teams are pre-determined and are closely coordinated with affected dealers by AVSpare Service Engineering with assistance from the respective Dealer Technical Communicators and AVSpare Service Representatives.

Additionally, the U/T inspection may be performed by the dealer or contracted to a qualified U/T inspection firm by the dealer. In this case, the inspection must follow the exact process detailed in Special Instruction, REHS4570. If the special instruction U/T inspection procedure can not be performed exactly as described, inspection by AVSpare U/T team or cylinder replacement are the only options allowed by this Service Letter.

Option B.) Preventative replacement of suspect cylinders (no inspection):

If the ultrasonic test inspection is not the option to be performed, suspect cylinders must be preventatively replaced with new cylinders of the same part number.

Note: When replacing any hydraulic cylinder, refer to the specific machine's "Disassembly and Assembly" portion of the Service Manual. Review, understand, and adhere to all safety and environmental warnings and notices associated with the removal and installation of hydraulic cylinders in each instance.

Parts Ordering:

All dealers who are either replacing suspect cylinders or changing a cylinder that did not pass the U/T inspection are requested to order new cylinders. Due to the shortage of available parts, back orders are likely. AVSpare Service Engineering, with assistance from the respective Dealer Technical Communicators and AVSpare Service Representatives, are manually coordinating priorities for order fulfillment for each affected dealer. AVSpare will do everything possible to expedite your orders.

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Image1

OWNER NOTIFIAVSION

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

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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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 1.0-hour job
The 1.0 hour allowance is to remove the machine from service. An additional allowance of $150 USD per cylinder will apply to dealer performed or contracted U/T inspection that meets the requirements of REHS4570. In the case of cylinder replacement, an additional 2.0 hours per cylinder will be allowed for removal and installation.

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PARTS DISPOSITION

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****Parts Stock****

Cylinders with date codes within the suspect range and rod assemblies with part numbers matching those shown in Image 1 (table of models - part numbers - applications shown below "Affected Model" information) and found in dealer stock are to be quarantined and held for 90 days. During that time, additional cylinder and rod handling information may be shared with the dealer. If not, at the end of 90 days, please handle the parts in accordance with the warranty bulletin.

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****Affected Product****

Cylinders failing the U/T inspection and cylinders with date codes within the suspect range that have been replaced are to be quarantined and held for 90 days. During that time, additional cylinder handling information may be shared with the dealer. If not, at the end of 90 days, please handle the parts in accordance with the warranty bulletin.

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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 REMOVING MACHINES FROM SERVICE AND INSPECTING/REPLACING CYLINDERS

MODELS INVOLVED - 320D, 321D, 324D, 325D, AND 328D EXCAVATORS

Dear AVSpare Product Owner:

Certain machines need to be removed from service and the cylinder rod(s) need to be inspected and/or replaced on the products listed below. The existing cylinder rod may have a weld defect that can cause the cylinder rod to separate from the rod eye. The cylinder rod can fail unexpectedly at any time during machine operation and presents a risk of personal injury or death. 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 20Mar2008 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 20Mar2008 Service Letter