PRODUCT SUPPORT PROGRAM FOR REWORKING THE BASE FRAME ON CERTAIN 345D AND 349D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE BASE FRAME ON CERTAIN 345D AND 349D EXCAVATORS

Usage:

REBE9318-00

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19Mar2013

D-99

O-103

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE BASE FRAME ON CERTAIN 345D AND 349D EXCAVATORS
4150 7062		PS52412

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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 "PS52412" 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

31Mar2015

PROBLEM

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Cracks in the lower ring internal fillet weld can occur on certain 345D and 349D Excavators. If a crack is found in this area it could result in catastrophic damage of the base frame.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
345D L	BYC00152-00163 DPA00192-00194 PBT00435-00465, 467-489, 500-505, 507-530, 535, 541-542, 546, 548, 550-556, 558, 560, 562, 564, 567, 570-571
349D L	NNF00109-00110, 115-131, 133-135, 137-139, 148-153, 161-169, 171-176, 179, 182-184, 186, 192-193, 198, 200, 202-204, 206-207, 209-212, 217-219, 221-224, 240, 243-245, 250 WTD00109-00135

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*****Group 2*****
349E	RGH00146

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*****Group 3*****
345D	FES00164-00176 NEG00497-00498, 502, 510, 520, 522-535, 541-542, 567, 574-578, 595-596, 599, 602, 604, 606, 610
349D	MEN00207-00208, 253, 259-260, 302, 304-305, 316-319, 321-322, 324, 326, 328, 331-332, 334, 337-341, 344, 351-356, 358, 373

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*****Group 4*****
349E L	WHZ00137

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
12	1P3703	SEAL-RECTANGULAR
6	1P3704	SEAL-RECTANGULAR
1	1U8846	SEALANT-GASKET
4	3D2824	SEAL-O-RING
2	3J1907	SEAL-O-RING
1	5K9090	SEAL-O-RING-ORFS
3	6V8397	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
2	6Y0473	PLUG-CLEAR
2	7G4332	STOPPER-RUBBER
6	7K1181	STRAP-CABLE
16	1504742	NUT-TRACK
1	2276105	BOOT
4	2517757	SEAL AS-MASTER
4	2518364	RING-THRUST MSTR
2	2532740	PIN-TRACK MASTER
16	3012299	BOLT-TRACK
1	3446891	FRAME AS-UNDCRG
1	PC23016	GP GREASE 50 (43Kg)
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*****
12	1P3703	SEAL-RECTANGULAR
6	1P3704	SEAL-RECTANGULAR
1	1U8846	SEALANT-GASKET
4	3D2824	SEAL-O-RING
2	3J1907	SEAL-O-RING
1	5K9090	SEAL-O-RING-ORFS
3	6V8397	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
2	6Y0473	PLUG-CLEAR
2	7G4332	STOPPER-RUBBER
6	7K1181	STRAP-CABLE
16	1504742	NUT-TRACK
1	2276105	BOOT
4	2517757	SEAL AS-MASTER
4	2518364	RING-THRUST MSTR
2	2532740	PIN-TRACK MASTER
16	3012299	BOLT-TRACK
1	3324987	FRAME AS-UNDCRG
1	PC23016	GP GREASE 50 (43Kg)
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*****
12	1P3703	SEAL-RECTANGULAR
6	1P3704	SEAL-RECTANGULAR
1	1U8846	SEALANT-GASKET
4	3D2824	SEAL-O-RING
2	3J1907	SEAL-O-RING
1	5K9090	SEAL-O-RING-ORFS
3	6V8397	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
2	6Y0473	PLUG-CLEAR
2	7G4332	STOPPER-RUBBER
6	7K1181	STRAP-CABLE
16	1504742	NUT-TRACK
1	2276105	BOOT
4	2517757	SEAL AS-MASTER
4	2518364	RING-THRUST MSTR
2	2532740	PIN-TRACK MASTER
16	3012299	BOLT-TRACK
1	3446888	FRAME AS-UNDCRG
1	PC23016	GP GREASE 50 (43Kg)
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*****
12	1P3703	SEAL-RECTANGULAR
6	1P3704	SEAL-RECTANGULAR
1	1U8846	SEALANT-GASKET
4	3D2824	SEAL-O-RING
2	3J1907	SEAL-O-RING
1	5K9090	SEAL-O-RING-ORFS
3	6V8397	SEAL-O-RING-ORFS
4	6V9746	SEAL-O-RING-ORFS
2	6Y0473	PLUG-CLEAR
2	7G4332	STOPPER-RUBBER
6	7K1181	STRAP-CABLE
16	1504742	NUT-TRACK
1	2276105	BOOT
4	2517757	SEAL AS-MASTER
4	2518364	RING-THRUST MSTR
2	2532740	PIN-TRACK MASTER
16	3012299	BOLT-TRACK
1	3324988	FRAME AS-UNDCRG
1	PC23016	GP GREASE 50 (43Kg)
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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If a crack is found on the lower ring fillet, repair the crack with the welding repair procedure in the attached Rework Procedure. Refer to Image1.

If the repair method is not clear because of severe damage, contact your local dealer Technical Communicator in order to obtain technical advice for the repair method.

Attach pictures and a report of base frame inspection results that shows the position of the crack. Refer to Image2.

IMPORTANT: Please do not place order of 344-6891, 332-4987, 344-6888, and 332-4988 Undercarriage Frame Assembly before communicating to Product Support for the repair.

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Image1

Image2

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*****
0-10000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-15000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 128.0-hour job for Group 1
Reasonable rental crane charge is covered by maximum 3 days. The service claim allowances based on machine ages/hours apply. 100% of the charge is covered by 10,000 hrs/36 months. 50% of the charge is covered by 15,000 hrs/60 months.

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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*****
0-10000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 128.0-hour job for Group 2
Reasonable rental crane charge is covered by maximum 3 days. The service claim allowances based on machine ages/hours apply. 100% of the charge is covered by 10,000 hrs/36 months. 50% of the charge is covered by 15,000 hrs/60 months.

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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*****
0-10000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-15000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 128.0-hour job for Group 3
Reasonable rental crane charge is covered by maximum 3 days. The service claim allowances based on machine ages/hours apply. 100% of the charge is covered by 10,000 hrs/36 months. 50% of the charge is covered by 15,000 hrs/60 months.

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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*****
0-10000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 128.0-hour job for Group 4
Reasonable rental crane charge is covered by maximum 3 days. The service claim allowances based on machine ages/hours apply. 100% of the charge is covered by 10,000 hrs/36 months. 50% of the charge is covered by 15,000 hrs/60 months.

PARTS DISPOSITION

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

Rework Procedure

Welding Repair Procedure

A. Upper Frame and Undercarriage Frame - Separate

When Base frame is repaired, some structures should be lifted for welding repair preparation. Refer to the following information if needed. Refer to Image1.1.1, 1.1.2, and 1.1.3.

1. Preparation

a) Crane
b) A jig and tool is required for a disassembly and assembly. Refer to RENR9574, Disassembly and Assembly.

2. Separation

Refer to RENR9574, Disassembly and Assembly, in order to separate the upper frame and undercarriage frame.

3. Weight information

Image1.1.1

Image1.1.2

Image1.1.3

B. Position the Lower frame For Welding Repair

Disassemble the track group and upper frame. Refer to RENR9574, Disassembly and Assembly. Repair a crack by completing the following procedure.

1. Remove the travel piping and connector for the swivel joint side. Install a shipping plug to the swivel joint and piping.

Refer to Image1.2.1, 1.2.2, 1.2.3, and 1.2.4.

Install Parts Needed:

6V-0400 Half Flange (Qty 8)
7I-7133 Cover (Qty 2)
8T-4194 Hex Head Bolt (Qty 16)
8T-4223 Head Washer (Qty 16)
9U-7335 Blocking Cover (Qty 6)
1P-3703 Rectangular Seal (Qty 4)
5P-0047 Cover (Qty 4)
6V-9508 Plug (Qty 1)
6V-9512 Plug (Qty 1)

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

2. Remove the idler and recoil spring. Refer to RENR9574, Disassembly and Assembly, "Front Idler, Recoil Spring and Hydraulic Track Adjuster -Remove".

3. Hook the wire into the traction hole on the base frame and lift the base frame up slowly. Refer to Image1.3.1.

Image1.3.1

4. Underlay the sleeper for protection of the sprocket and turn over the base frame. Refer to Image1.4.1.

Image1.4.1

5. Underlay the wood sleeper so that the swing bearing is not damaged. Then, place the base frame on the wood sleeper. Refer to Image1.5.1.

Image1.5.1

C. Welding Repair Procedure

1. To prevent heat damage by repairing the weld, marking numbers 1 to 8 are applied to the base frame. Refer to Image1.6.1.

Image1.6.1

2. Apply gouging to welded part, from 1 to 8 in turn, and perform the weld. Refer to Image1.7.1.

Note: Perform the gouging and welding at a diagonal in order to prevent heat stress. Perform gouging in the present welded part.

Image1.7.1

3. Gouging 20 to 30 mm from the end of welding is required. After the next welding is finished, they are then re-welded. Refer to Image1.8.1, 1.8.2, and 1.8.3.

Note: Refer to REHS1841, Special Instruction, General Welding Procedures.

Image1.8.1

Image1.8.2

Image1.8.3

4. Confirm welded condition. Grind the surface if needed. Refer to Image1.9.1.

Image1.9.1

5. Paint the repaired area on base frame.

D. Preparation for Assembly of the Upper Frame On to the Base Frame

1. Lift the base frame, by crane, and turn over. Refer to Image1.11.1.

Image1.11.1

2. Install the swivel joint. Refer to Image1.12.1.

Image1.12.1

3. Install a hose between the swivel joint and the travel motor.

4. Install the idler and recoil spring. Refer to RENR9574, Disassembly and Assembly, "Front Idler, Recoil Spring and Hydraulic Track Adjuster - Install".

5. Supply grease into the grease bus.

6. Apply sealant to swing bearing mounting surface. Refer to Image1.13.1.

Image1.13.1

E. Upper Frame and Undercarriage Frame - Connect

Refer to RENR9574, Disassembly and Assembly, in order to connect the upper frame and the undercarriage frame.