PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER RODS THAT HAVE SURFACE DISCOLORATION ON CERTAIN 320D, 324D, 325D, 330D, 345C EXCAVATORS (CONTAINMENT) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER RODS THAT HAVE SURFACE DISCOLORATION ON CERTAIN 320D, 324D, 325D, 330D, 345C EXCAVATORS (CONTAINMENT)

Usage:

REBE4483-00

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12Feb2009

J080
J440
J065
J012
J043
J050
J422
J441
J040
J045
J016
J490
J480
J039
J420
J044
J540
J421
J010
J027
J049

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After Failure Only (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING CYLINDER RODS THAT HAVE SURFACE DISCOLORATION ON CERTAIN 320D, 324D, 325D, 330D, 345C EXCAVATORS (CONTAINMENT)
5456 5457 5458		PS51626

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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 "PS51626" 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 Caterpillar product analyst.

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TERMINATION DATE

28Feb2011

PROBLEM

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Discoloration (blackening) of the cylinder rods may occur on certain 320D, 324D, 325D, 330D and 345C Excavators. Discoloration typically happens on single cylinders only. The appearance of discoloration impacts the quality perception. There is no known impact on the performance or reliability of the machine.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
345C	BWY00104, 120-122, 124-130, 134-135, 137-139, 141-145, 147-148, 151, 153-154, 157-165, 168-170, 174-178, 181-189, 205-209, 211-214, 217-218, 220, 222, 248, 253, 255-263, 283, 285-290, 292, 296-306, 310, 314, 318, 327, 330, 333, 335, 338, 340, 342 DHP00449-00451, 453, 457-458, 461-463 TBA00152-00154, 157, 159, 168, 178, 180, 182-183, 188, 206-207, 269-271, 277, 279-281, 283-284, 292, 296, 299, 361-363, 365, 367, 399, 429, 433, 444, 448 WDE00142-00145, 158, 163, 166

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*****Group 2*****
330D	MEY00183-00184, 189-193, 196-197, 207-209, 211, 233-238, 240-243, 250, 252, 264-268, 272, 275, 280-282, 284-287, 290-291, 293-294, 296, 318, 322, 324-325, 329-330, 334, 347-349, 355-367, 381, 383, 406, 408-418 NBD00251-00252, 289-292, 311-312, 385-386, 390-391, 398-400, 473-475, 504, 569, 578, 791, 793, 795, 797, 832, 836-837, 840-843, 846, 930, 936, 938, 1027-1029, 1087, 1120, 1143, 1207, 1236, 1319, 1321
330D L OEM	H3D00149, 202

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*******Group 3*******

325D

KDG00171-00172, 218-231, 253-259, 261-263, 265-266

SCR00267, 279-282, 289, 291, 293, 352-354, 374-375, 385-387, 415-416, 425-426, 441-442, 445-449, 457-459, 463, 468-470, 477, 481, 483, 485, 487-489, 491, 493-495, 506, 509, 667, 671, 679, 681, 690, 693-694, 708, 711, 719, 731, 746-748, 750, 752-754, 805, 838, 841-843, 865, 867-868, 870, 875-876, 878-879, 897, 908, 915, 922, 924, 928, 935, 940, 950, 955, 957-962, 964, 968-970, 972, 982-983, 1010

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*****Group 4*****
324D	CJX00189, 198-206, 208, 210-214, 216-218, 221-223, 225-238, 241-243, 245-254, 256-258, 260-263, 268-275, 278, 280-295, 297-299, 301-303, 305-311, 314-319, 323-325, 328-333, 337, 346-359, 361-362, 366-376, 378, 380-381, 383-393, 401-424, 431, 433-441, 446
324D L	DFP00164, 183, 190-191, 213-214, 216, 280, 283-285, 302, 314-315, 318, 320, 322, 324-325, 392-393, 397, 466, 470

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*******Group 5*******

320D

CXY00250, 318-323, 336, 346-357, 359-360, 374, 376-381, 384-391, 394, 396-404, 406-407

FAL00177-00181, 215, 229, 245-248, 251-253, 256-274, 295-296, 299-302, 305, 309-311, 314-320, 322-326, 331-332, 334-335, 337, 340, 378, 390-391, 400-401, 437-439, 443, 445, 468-470, 472-475, 477, 479-480, 483-485, 490-491, 495, 497-499, 502, 505-510, 512-514, 517, 519, 523, 537-540, 545, 550-551, 557-563, 567, 569-570, 597-598, 636, 642-643, 646, 674-675, 688, 699-702, 718-719, 721, 733-734, 737-741, 763, 766-769, 779, 784, 787-788, 790-794, 796-802, 804, 819-826, 833-836, 891, 901-903, 916, 932, 963-964, 968-987, 1012-1013, 1015-1019, 1022-1025, 1042, 1047, 1050, 1052, 1055-1058, 1061-1065, 1257, 1259, 1275-1285, 1287, 1289-1303, 1306-1307, 1309-1311, 1315-1317, 1319-1320, 1324-1325, 1338, 1419-1420, 1427-1448, 1450-1466, 1469, 1479, 1481, 1495, 1498, 1500, 1509, 1512-1516, 1518-1533, 1536-1540, 1546-1547, 1552, 1558-1562, 1568-1570, 1578, 1585, 1642, 1644-1646, 1650-1655, 1657-1662, 1664-1665, 1667-1671, 1673-1676, 1678, 1683, 1685, 1691-1696, 1701-1706, 1708-1712, 1716-1717, 1884-1891, 1895, 1898, 1900-1906, 1912-1913, 1916-1919, 1921, 1924, 1928, 1930-1932, 1938-1941, 1943-1951, 1977, 2006

KGF01172, 1223, 1226, 2461, 2586

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	0R9073	ROD AS-HYD (as required)
1	0R9164	ROD AS-HYD (as required)
1	10R6996	ROD AS-HYD (as required)
1	10R6998	ROD AS-HYD (as required)
1	2254625	SEAL KIT (as required)
1	2254646	SEAL KIT (as required)
1	2344442	SEAL KIT (as required)
3	3096940	OIL (as required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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*****
1	0R9073	ROD AS-HYD (as required)
1	1915619	SEAL KIT (as required)
1	1948235	SEAL KIT (as required)
1	2254625	SEAL KIT (as required)
1	2316844	SEAL KIT (as required)
1	2316845	SEAL KIT (as required)
1	2426787	ROD AS (as required)
1	2426840	SEAL KIT (as required)
1	2502475	SEAL KIT (as required)
1	2898027	ROD AS (as required)
1	2898037	ROD AS (as required)
2	3096940	OIL (as required)
1	3096944	OIL (as required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 3*****
1	1915619	SEAL KIT (as required)
1	2344566	SEAL KIT (as required)
1	2344568	ROD AS (as required)
1	2344576	SEAL KIT (as required)
1	2344578	ROD AS (as required)
1	2344587	SEAL KIT (as required)
1	2344589	ROD AS (as required)
1	2426787	ROD AS (as required)
1	2502475	SEAL KIT (as required)
1	2590648	SEAL KIT (as required)
1	2590650	SEAL KIT (as required)
1	2590656	SEAL KIT (as required)
1	2590779	SEAL KIT (as required)
1	3096940	OIL (as required)
7	3096944	OIL (as required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 4*****
1	2478878	SEAL KIT (as required)
1	2478887	ROD AS (as required)
1	2478888	SEAL KIT (as required)
1	2478974	SEAL KIT (as required)
1	2590660	ROD AS (as required)
1	2590665	SEAL KIT (as required)
1	2590672	ROD AS (as required)
1	2590674	ROD AS (as required)
1	2590678	SEAL KIT (as required)
1	2590774	SEAL KIT (as required)
1	2590775	SEAL KIT (as required)
1	2590776	SEAL KIT (as required)
1	2667892	SEAL KIT (as required)
1	3096940	OIL (as required)
4	3096944	OIL (as required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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 5*****
1	2478867	ROD AS (as required)
1	2478868	SEAL KIT (as required)
1	2478877	ROD AS (as required)
1	2478878	SEAL KIT (as required)
1	2478882	ROD AS (as required)
1	2478887	ROD AS (as required)
1	2478888	SEAL KIT (as required)
1	2478974	SEAL KIT (as required)
1	2590775	SEAL KIT (as required)
1	2667891	SEAL KIT (as required)
1	2667892	SEAL KIT (as required)
1	2667929	SEAL KIT (as required)
1	2667939	ROD AS (as required)
1	3096940	OIL (as required)
4	3096944	OIL (as required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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1) The affected (discolored) cylinder group needs to be identified and the discoloration verified.
2) Pictures must be taken and added to the claims report. Each affected cylinder must be documented by a picture of the component ID plate and discoloration area.
3) If the rod surface shows consistent discoloration (blackening), the affected rod can be replaced under this program.
4) Refer to the rework procedure for details.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-4000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 1
Customer participation (for hydraulic oil replacement cost) should be considered in cases where the recommended hydraulic oil change interval has not been followed. Refer to the machine OMM for maintenance interval details.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-4000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 2
Customer participation (for hydraulic oil replacement cost) should be considered in cases where the recommended hydraulic oil change interval has not been followed. Refer to the machine OMM for maintenance interval details.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-4000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 3
Customer participation (for hydraulic oil replacement cost) should be considered in cases where the recommended hydraulic oil change interval has not been followed. Refer to the machine OMM for maintenance interval details.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-4000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 4
Customer participation (for hydraulic oil replacement cost) should be considered in cases where the recommended hydraulic oil change interval has not been followed. Refer to the machine OMM for maintenance interval details.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-4000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 10.0-hour job for Group 5
Customer participation (for hydraulic oil replacement cost) should be considered in cases where the recommended hydraulic oil change interval has not been followed. Refer to the machine OMM for maintenance interval details.

PARTS DISPOSITION

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

Rework Procedure

NOTE: Refer to the machines Disassembly and Assembly Manual for details.

1. Remove the affected cylinder group from the machine.
2. Replace the cylinder rod and seal kit.
3. Install the cylinder group on the machine.
4. Replace all the oil in the machine hydraulic system. Refer to the Operation and Maintenance Manual for details.