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

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

Usage:

REBE9457-01

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22Apr2013

(Revised 17May2013)

D-139

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE BASE FRAME ON CERTAIN 345D AND 349D EXCAVATORS
4150 7062 0679		PS43892

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43892" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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 Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 22Apr2013 Service Letter. Changes have been made to the Service Claim Allowance hour months.

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TERMINATION DATE

30Apr2015

PROBLEM

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The existing base frame can be cracked on the lower ring internal fillet weld on certain 345D and 349D Excavators. The crack will cause catastrophic damage of base frame. If the existing base frame is cracked, it can be repaired according to the following Rework Procedure.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
345D	NEG00495-00496, 499-501, 503-509, 511-519, 521, 536-540, 543-566, 568-571, 579-581, 583-591, 597-598, 600-601, 603, 605, 607-609, 611-616
349D	MEN00172-00206, 209-252, 254-258, 261-301, 303, 306-309, 311-315, 320, 323, 327, 329-330, 333, 336, 342-343, 345-350, 360-361, 363-365, 367-372

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*****Group 2*****
345D L	PBT00466, 490-499, 506, 531-534, 536-540, 543-545, 547, 549, 557, 559, 561, 563, 565-566, 568-569, 572-587
349D L	NNF00108, 111-114, 132, 136, 140-147, 154-160, 170, 177-178, 180-181, 185, 187-191, 195-197, 199, 201, 205, 208, 213-216, 220, 225-239, 241-242

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	3446888	FRAME AS-UNDCRG
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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	3446891	FRAME AS-UNDCRG
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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This program requires inspection before/after failure.

Inspect the machine in order to find a crack on the lower ring internal fillet. If a crack is found, please contact your local dealer Technical Communicator with failure photo in order to obtain technical advice for the repair method or replacement. Upload photo for repaired base frame to SIMSi when claiming against the Service Letter.

Due to the worldwide parts constraint, the following parts listed are on 207 freeze: 344-6888 and 344-6891 Frame Assembly Undercarriage. Orders will be prioritized and released as quickly as possible by the World Wide Excavator Product Support Group.

If a crack is found, please follow the decision tree in Image1 in order to choose the appropriate repair procedure.

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Image1

Image2

Image3

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, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 1
2.0 hours will be allowed for inspection of the base frame. If the repair is to be performed by Cat welder with overhead welding, an additional 32.0 hours and 2 barrels/18L Hydraulic oil will be allowed to claim. If the repair is to be performed by disassembling U/F, an additional 128.0 hours, 4 barrel/18L Hydraulic oil, and 2 barrel/18L Grease oil will be allowed to claim. If the repair is to be performed by B/F replacement, an additional 125.0 hours, 4 barrel/18L Hydraulic oil, and 2 barrel/18L Grease oil will be allowed to claim.

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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%
10001-15000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 2
2.0 hours will be allowed for inspection of the base frame. If the repair is to be performed by Cat welder with overhead welding, an additional 32.0 hours and 2 barrel/18L Hydraulic oil will be allowed to claim. If the repair is to be performed by disassembling U/F, an additional 128.0 hours, 4 barrel/18L Hydraulic oil, and 2 barrel/18L Grease oil will be allowed to claim. If the repair is to be performed by B/F replacement, an additional 125.0 hours, 4 barrel/18L Hydraulic oil, and 2 barrel/18L Grease oil will be allowed to claim.

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 the base frame is repaired, some structures should be lifted for welding repair preparation. Refer to the following information if needed.

1. Preparation

a) Crane
b) A jig and tool required. 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 - Refer to Images1.1.1, 1.1.2, and 1.1.3

Image1.1.1

Image1.1.2

Image1.1.3

B. Lower Frame Positioned for Welding Repair

The track group and upper frame need to be disassembled. Refer to RENR9574, Disassembly and Assembly, for the procedure. Next, repair the crack with the following Rework Procedure.

1. Remove the travel piping and connector for the swivel joint side, and install shipping plug to the swivel joint and piping.

Install the following parts. Refer to Images1.2.1, 1.2.2, 1.2.3, and 1.2.4 for the locations.

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. Lift the base frame up slowly. Refer to Image1.3.1.

Image1.3.1

4. Underlay a wood 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 a swing bearing may not be damaged. Then place the base frame on the wood sleeper. Refer to Image1.5.1.

Image1.5.1

C. Welding Repair

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

Image1.6.1

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

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

Image1.7.1

3. Gouge 20 to 30mm from the end of the weld. Once the next weld is completed, they will need to be re-welded. Refer to Images1.8.1, 1.8.2, and 1.8.3.

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 the base frame.

D. Preparation for Assembly of the Upper Frame on to the Base frame

1. Lift the base frame with a 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 the recoil spring. Refer to RENR9574, Disassembly and Assembly, "Front Idler, Recoil Spring and Hydraulic Track Adjuster - Install".

5. Supply grease into 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.