PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOOM LOAD PLUGS ON CERTAIN 320C, 320C L, 322C, 325C AND 330C EXCAVATORS

Usage:

SEBE8691

March 13, 2004
D-52

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BOOM LOAD PLUGS ON CERTAIN 320C, 320C L, 322C, 325C AND 330C EXCAVATORS
5051		PI10292

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10292" 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 "PI10292" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The boom load plugs need to be replaced on certain 320C, 320C L, 322C, 325C and 330C Excavators. The main control valve with shaft seal plugs improves oil transfer from control valve with O-ring seal plugs. Sudden accelerated swing motion occurs under boom and swing simultaneous operation due to oil leaking from boom plug on machines installed 2366420 Boom Load Hold Plug in main control valve. It causes oil transfer from boom load hold plug by unsteady declining movement due to short length 6.48 mm of guide between plug and check valve.

AFFECTED PRODUCT

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Model	Identification Number
320C	AMC3460, 3461, 3647-3649, 3655-3657, 3664, 3665, 3672-3674, 3680-3682, 3686-3694, 3696-3698, 3761, 3768 BPR4928-4931, 4936, 4940, 4941, 4944, 4946, 4947, 4956, 4957, 4960, 4966, 4967, 4971, 4972, 4992-4996, 5009-5013, 5036-5040, 5064-5068, 5092-5096, 5114-5118, 5131, 5243
320C L	ANB3799-3807, 3809, 3811-3815, 3818, 3819, 3830, 3831, 3833
322C	FED189
325C	AMH369-372, 374
330C	MCA449, 451, 452, 460 JAB637, 640-642, 644 KDD595-597, 599-602

PARTS NEEDED

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Qty	Part Number	Description
1	0951590	Seal
1	0951787	Seal
1	2502446	Plug

ACTION REQUIRED

See the attached Rework Procedure. Note: The part number of Travel Hold plug is same as the part number of Boom II Load Hold plug, but it is not necessary to replace travel hold plug. This problem does not occur with the travel hold plug.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1	0	0	0	0
NOTE: This is a 1-hour job.

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.

Attach. (1-Sample of Owner Notification)
(2-Rework Procedure)

SAMPLE OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - Replace The Boom Load Plugs

MODELS INVOLVED - 320C, 320C L, 322C, 325C and 330C Excavators

Dear Caterpillar Product Owner:

The boom load plugs need to be replaced on certain 320C, 320C L, 322C, 325C and 330C Excavators. The main control valve with shaft seal plugs improves oil transfer from control valve with O-ring seal plugs. Sudden accelerated swing motion occurs under boom and swing simultaneous operation due to oil leaking from boom plug on machines installed 2366420 Boom Load Hold Plug in main control valve with a potential for serious injury or death. It causes oil transfer from boom load hold plug by unsteady declining movement due to short length 6.48 mm of guide between plug and check valve. A new plug needs to be installed on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar 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 March 13, 2004 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added personal safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to March 13, 2004 Service Letter

Rework Procedure

Replace the former 2366420 Plug - Boom Load with a new 2502446 new Plug - Boom Load (length 12.98 mm of guide between plug and check valve) using the following procedure and Illustration 1. The main control valves with axial seal plugs are shown in Table 1.

Table 1 - Main Control Valve part numbers

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Model	Part number	Description
320C 320CU	2403019	Control Valve GP (R/H)
320C 320CU	2403020	Control Valve GP (L/H)
321CCR	2403019	Control Valve GP (R/H)
321CCR	2398770	Control Valve GP (L/H)
322C	2403058	Control Valve GP (R/H)
322C	2403059	Control Valve GP (L/H)
325C	2403064	Control Valve GP (R/H)
325C	2403065	Control Valve GP (L/H)
330C	2366424	Control Valve GP (R/H)
330C	2406425	Control Valve GP (L/H)

Procedure to rework

Remove the former 2366420 Plug - Boom Hold in main control valve on 320C(L) to 330C(L). The part number of these control valves is shown at Table 1.
Sweep hole of this plug by removing oil.
Install 2502446 new boom hold plug in main control valve including new 0951590 Seal and new 0951787 Seal. The U-groove identification is marked at head of new 2502446 Plug at right side figure in Illustration 1. Tighten new 2502446 Plug - Boom Hold to a torque of 240 +20/-0 N.m.
Check hydraulic line and machine performance according to service manual.