PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM ON CERTAIN M325C AND M325D MATERIAL HANDLERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM ON CERTAIN M325C AND M325D MATERIAL HANDLERS

Usage:

REBE2189-01

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12Jul2007

(Revised 26Oct2007)

U-320

A-261

O-291

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM ON CERTAIN M325C AND M325D MATERIAL HANDLERS
6501		PI10609

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10609" 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 "PI10609" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 12Jul2007 Service Letter. Changes have been made to the Service Claim Allowances and the Rework Procedure.

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PROBLEM

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Cracks can appear in the boom nose welds on certain M325C and M325D Material
Handlers. The boom welds need to be inspected and the boom nose needs to be reinforced. The existing boom can break due to the cracks in the welds. The stick can then fall down and this may result in personal injury or death. The boom nose needs to be inspected and reinforced with doubler plates.

AFFECTED PRODUCT

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Model	Identification Number
M325C MH	PAN00242-00257, 259-275, 279, 282-283, 285-290, 295, 297-304, 306-312, 315-334, 336, 338-343 XJA00202-00292
M325D L MH	KAY00231-00234, 236-237, 239, 242-244, 246 KGG00211-00212, 221-227
M325D MH	EDF00221-00248, 250-256

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 24.0-hour job
An additional 6 hours will be allowed if ultrasonic testing is done by dealers personnel

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PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM

MODELS INVOLVED - M325C AND M325D MATERIAL HANDLERS

Dear Caterpillar Product Owner:

The boom needs to be inspected and reworked on the products listed below. The existing boom can break due to the cracks in the welds. The stick can then fall down and this may result in personal injury or death. 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 12Jul2007 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 12Jul2007 Service Letter

Rework Procedure

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Remove the stick and boom from the machine and plug the hydraulic connections. Refer to the machines Disassembly and Assembly Manual.
Make a visual inspection of all boom welds.
Perform an Ultrasonic test of the boom nose welds from A to B (See Image 1.1.2) to identify possible cracks between side plates and boss.

Ultrasonic test made by certified specialist is mandatory prior to rework.
Data for Ultrasonic apparatus setup is given in Image 1.1.2.

Image1.1.1

Image1.1.2

If a crack is found, please contact Product Support Service Engineer Christian M?hle (email: Muhle_Christian@cat.com, phone: + 32 71 25 2559) for further
instructions.

If no cracks are found at boom nose welds, perform the following boom nose reinforcement:

Welding Requirements:

Welding quality is critical to the success of the installation procedure. Welds
must be smooth and continuous. No undercutting is allowed. No overlap is
allowed. Grind the ends of the welds to a smooth radius.
Prepare the metal for welding according to ? Preparing the Metal for Welding?.
Refer to the illustrations in this Special Instruction for welding symbols and
specifications.
Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to
weld the reinforcement plates to the structure. Basic welding wire ESAB OK
tubrod 15.00 with a 1,2 mm (0,05 inch) diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E17T-5 with positive
polarity. The welding wire must be shielded with CO? gas.
Welding of the gouged grooves requires LB-52 (AWS E7018), or an equivalent
electrode. Basic welding wire ESAB OK tub rod 15.00 with a 1,2 mm (0,05 inch)
diameter can also be used.
All electrodes must be completely dried. The electrodes can be dried by heating
the electrodes to 300?C (572?F). The electrodes must be dried for at least 30
minutes.
Do not weld in windy conditions. Do not weld when temperatures are below
16?C (60?F).
Penetration characteristics may vary greatly depending on the electrode
diameter, shielding gas, welding current and plate thickness. Geometry of
welded joints, surface conditions and composition of the base metal and
electrode also affect welds.
A root pass should be applied before each weld is finished.
For more welding information, consult the Caterpillar Service Welding Guide,
SEBD0512.

Preparing the Metal for Welding:

Prepare Reinforcement plates (2 per boom) following given dimensions (See Image 1.3.1)using Steel Material S355J2G3 EN10025

Image1.3.1

Cover all finished bores and threads. Finished bores and threads must be
protected from all of the following items: foreign material, gouging and paint
spatters.
All grease, water, paint, rust, dirt and scale must be removed before welding.
Any of these materials will discharge gas, which will cause porosity in the weld deposit. Water and rust will cause hydrogen embrittlement. Hydrogen
embrittlement causes cracks in the weld deposit.
Remove paint, rust, dirt and scale with a wire brush or by buffing or grinding.
Shot blasting all work areas will also remove foreign material.
Remove any oil or grease that is on the boom with a Caterpillar approved
solvent.

Repair instruction:

Put the boom with its side in horizontal position for each welding operation of the reinforcement plates. This will ensure that welding operation is done in the best conditions(horizontal).

1. Clean the boom. Remove all foreign material and paint from the weld areas.
Refer to ?Preparing the Metal for Welding? for more instructions.

2. Grind weld seam between side plate and boss assembly at boom nose, so that
reinforcement plate can be placed correctly (see Images 1.4.1 & 1.4.2).

3. Put reinforcement plate on boom nose and weld it according to drawing (see Image 1.4.1). Make a smooth transition at Point B between the two different fillet weld seams (See Images 1.4.1 & 1.4.2).

4. Grind weld transition at marked position to R5 minimum with a maximum undercut of
0.8mm.

Note that the weld between reinforcement plate and boss must have full penetration.
An Ultrasonic check of this final weld made by a certified specialist is mandatory to be sure of the full penetration and to assure safety of the rework.

Image1.4.1

Image1.4.2

Grinding of Weld seams:

Please grind weld seams on a length of 100mm at 12 places as shown in Images 1.5.1 and 1.5.2. Also grind weld seams all around PT2 and all around PT3 at each side of the boom(see Images 1.5.1 and 1.5.2). Maximum undercut permitted is 0.8mm.

Image1.5.1

Image1.5.2

Remove two blocks on top plate:

Remove two blocks welded on the top plate close to PT3. These blocks are located at 2004mm and 1904mm from boom nose Pt4 (See Image 1.6.1).
Grind these areas to even surfaces with a maximum undercut permitted of 0.8mm.

Image1.6.1

Painting and Coating the structure parts:

Shot blast all the welded areas. A wire brush or a grinder can also be used to
clean the welded areas.
Paint all the welds, plates and the frame. Use a Caterpillar authorized paint.
Remove all protective covers from the bores and threads once the paint has
dried.
Bores must be free of paint and grease prior to assembly of the bearings.
Assemble the boom, stick, and connect all hydraulic lines. Refer to the machines Disassembly and Assembly Manual.

Refer to the Operation and Maintenance Manual and Service Manual for
lubrication instructions and quantities.