PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 269-9639 RETURN LINES GROUP ON CERTAIN 328D EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 269-9639 RETURN LINES GROUP ON CERTAIN 328D EXCAVATORS [REBE3680]

HYDRAULIC SYSTEM

LINES GP-PUMP

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 269-9639 RETURN LINES GROUP ON CERTAIN 328D EXCAVATORS

REBE3680-00

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18Aug2008

U-425

D-351

O-389

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 269-9639 RETURN LINES GROUP ON CERTAIN 328D EXCAVATORS
5057		PI31550

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31550" 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 "PI31550" 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
28Feb2009	31Aug2009

PROBLEM

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The 269-9639 Return Lines Group needs to be reworked on certain 328D Excavators. Leaks are occurring at the interface of the hose and pipe due to pressure levels that exceed the hose and clamp design pressure specification. Design improvement has been made and the existing population needs to be reworked to reflect the update.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
328D	GTN00105-00143, 145-146, 148-151, 153-164, 166-167, 169, 171-175, 177-179, 181-189, 191-193, 195-196, 198-201, 203-212, 214-216, 218-227, 229-237, 240, 242-244, 248-287, 289-292, 294-311, 314-315, 317-320, 322-323, 326, 328, 330, 333-337, 342-354, 356, 358, 360, 363-391
328D LCR OEM	JTC00101

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*****Group 2*****
328D	GTN00104, 144, 147, 152, 165, 168, 170, 176, 180, 190, 194, 197, 202, 213, 217, 228, 238-239, 241, 245-247, 288, 293, 312-313, 316, 321, 324-325, 327, 329, 331-332, 338-341, 355, 357, 359, 361-362

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
4	1P4579	FLANGE-HALF
3	4J0524	SEAL-O-RING
24	8T4223	WASHER-HARD
12	8T4956	BOLT
2	9X2014	OIL
1	3200087	PIPE AS
1	3200089	PLATE
1	3200090	PIPE AS
1	3200095	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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	1P4579	FLANGE-HALF
1	3D2824	SEAL-O-RING
3	4J0524	SEAL-O-RING
1	6V9004	ELBOW-45 DEG ORF
1	6V9746	SEAL-O RING
24	8T4223	WASHER-HARD
12	8T4956	BOLT
2	9X2014	OIL
1	1335770	HOSE AS
1	3200087	PIPE AS
1	3200089	PLATE
1	3200090	PIPE AS
1	3200095	HOSE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 1

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 2

PARTS DISPOSITION

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 269-9639 RETURN LINES GROUP

MODELS INVOLVED - 328D EXCAVATORS

Dear AVSpare Product Owner:

The return lines group needs to be reworked on the products listed below. The existing return lines group can fail. 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 18Aug2008 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 18Aug2008 Service Letter

Rework Procedure

Group Number 1

1) Remove the 269-9639 Rear Lines Group. Refer to Image 1.1.1. Remove 314-8257 Pipe Assembly (a), 314-8258 Pipe Assembly (b), 272-4485 Pipe Assembly (c), 272-4572 Support Assembly (d), 272-4503 Support Assembly (e), 272-4494 Support Assembly (f), 314-8256 Hose (g) 2pcs, 8T-4984 Clamp (h) 6pcs, 7Y-5238 U-bolt (i) 3pcs, and 148-8408 Plug Assembly (j).

Image1.1.1

2) Reuse the 272-4503 Support Assembly (e), 7Y-5238 U-bolt (h) 1pc, and 148-8408 Plug Assembly (i).
3) Install new pipe assembly and hose assembly. Refer to Image 1.1.3. Connect 320-0090 Pipe Assembly (c), 272-4503 Support Assembly (e), and 7Y-5238 U-bolt (i). Connect 320-0087 Pipe Assembly (a) and 148-8408 Plug Assembly (j). Connect 320-0089 Plate (d) on skirt frame. Connect 320-0095 Hose Assembly (k).

Image1.2.1

Image1.2.2

Refill the hydralic oil.

Group Number 2

Image2.1.1

When using Attachment Pump lines Group,
1) Remove the 269-9661 Attachment Pump lines Group to change port position of standard return lines.
Remove 272-4593 Hose Assembly (m) and 148-8327 Connector Assembly (l).

Image2.2.1

2) Reuse 272-4503 Support Assembly (e), 7Y-5238 U-bolt (h) 1pc, and (i)148-8408 Plug Assembly.
3) Install new pipe Assembly and hose Assembly. Refer to Image 1.1.3. Connect 320-0090 Pipe Assembly (c), 272-4503 Support Assembly (e), and 7Y-5238 U-bolt (i). Connect 320-0087 Pipe Assembly (a) and 148-8408 Plug Assembly (j). Connect 320-0089 Plate (d) on skirt frame. Connect 320-0095 Hose Assembly (k).

Image2.3.1

Image2.3.2

Case of using Attachment Pump lines Group,
4) Install new hose assembly. Connect 133-5770 Hose Assembly (m), 6V-9004 Elbow (l), 3D-2824 Seal (n), and 6V-9746 Seal (o).