PRODUCT SUPPORT PROGRAM FOR REWORKING THE CYLINDER GUARDS ON CERTAIN 365B, 365C, 5090B AND 385C FRONT SHOVEL EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CYLINDER GUARDS ON CERTAIN 365B, 365C, 5090B AND 385C FRONT SHOVEL EXCAVATORS

Usage:

REBE2124-00

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16Nov2007

U-594

A-485

D-486

O-521

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CYLINDER GUARDS ON CERTAIN 365B, 365C, 5090B AND 385C FRONT SHOVEL EXCAVATORS
7164		PS51395

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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 "PS51395" 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

30Nov2009

PROBLEM

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The existing cylinder guards can fail on certain 365B, 365C, 5090B and 385C Front Shovel Excavators. If the existing guard clamps and bolts fail, replace the existing components with new components as described in the attached Rework Procedure. Refer to Image 1.1.1.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
385C FS	EAM00265-00279 MMA00245-00253 T2F00184-00188

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*****Group 2*****
365BL II	PEG00111-00122
365CL FS	PAR00250-00266

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*****Group 3*****
385C FS	EAM00264 T2F00181-00183
5090B	CLD00312-00350 SJY00106-00107

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
16	7X2555	BOLT
16	9X8257	WASHER
2	2693775	CLAMP AS.
16	2693777	SPACER
1	2940253	SUPPORT AS
1	3083683	SUPPORT AS
2	3086505	CLAMP AS.
2	3088399	SUPPORT AS
4	3088402	CLAMP AS.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% of dealership population. This is an inital 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*****
16	7X2555	BOLT
16	9X8257	WASHER
4	2633659	SHAFT
2	2693775	CLAMP AS.
16	2693777	SPACER
4	2853025	CLAMP AS.
1	2864076	CHANNEL AS.
2	2864077	SUPPORT AS.
2	2873341	CLAMP AS.
1	2914090	SUPPORT AS.
1	2940253	SUPPORT AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% of dealership population. This is an inital 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*****
16	7X2555	BOLT
16	9X8257	WASHER
1	2633657	CHANNEL AS
4	2633659	SHAFT
2	2693775	CLAMP AS.
16	2693777	SPACER
1	2940253	SUPPORT AS
1	3083683	SUPPORT AS
2	3086505	CLAMP AS.
2	3088399	SUPPORT AS
4	3088402	CLAMP AS.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% of dealership population. This is an inital 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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Please refer to the attached Rework Procedure.

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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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 8.0-hour job for Group 1

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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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 8.0-hour job for Group 2

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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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 37-60 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 8.0-hour job for Group 3

PARTS DISPOSITION

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

Rework Procedure

Disassemble all guard channels and support assemblies for the boom cylinders, master cylinder and stick cylinder. Although some guards might be reusable, the new guard components have to be assembled on all cylinders to avoid interference between the old designs and the new designs.

Image1.1.1

Replace the guard parts with the new parts given in the following tables:
Refer to Image 1.2.1. for parts assembly, Image 1.2.2 for parts for Group 1, Image 1.2.3 for parts for Group 2 and Image 1.2.4 for parts for Group 3.

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

Note the assembly location of the new shafts (Refer to Image 1.3.1) for the stick cylinder guard of Group 2 and for the master cylinder of Group 3. Assemble shafts with existing ball bearings on the new channel assembly.

Image1.3.1

Correctly locate the support assemblies and clamps on the cylinders. Refer to Images 1.4.1 and 1.4.2.

Image1.4.1

Image1.4.2

Reassemble components, tighten channels shafts and bolts (M12 Bolts) to a torque of 100 Nm +/- 20 Nm and cylinder clamps (M16 Bolts) to a torque of 240 Nm +/- 40 Nm (Refer to Image 1.5.1).