PRODUCT SUPPORT PROGRAM FOR REWORKING BUCKETS ON CERTAIN 312C, 312D, 315C, AND 315D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING BUCKETS ON CERTAIN 312C, 312D, 315C, AND 315D EXCAVATORS

Usage:

REBE4845-00

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06Aug2009

D-254

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING BUCKETS ON CERTAIN 312C, 312D, 315C, AND 315D EXCAVATORS
6102 0679		PS51706

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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 "PS51706" 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

31Aug2011

PROBLEM

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The bucket may crack at the torque tube top plate weld joint on certain 312C, 312D, 315C, and 315D Excavators or bucket bracket ear deformation may occur on certain 315C and 315D Excavators due to the severity of the machine application.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
312C	FDS00660-00661, 663-665, 667, 669, 671, 673, 677, 693, 695, 698, 701, 704, 706, 708, 710-711, 714, 735-736, 738-740, 743, 745-749, 751-760, 763-764, 769-785, 787-790, 792-797
312C L	CBA04670-04673
312D	DLP00186-00389 HCW00108-00115, 117-118, 120, 122, 124, 126, 128, 139, 143, 145, 147-157, 160, 162, 166-179, 183-189, 191-197, 201, 215, 217-221, 223-226, 228-230, 232-235, 245, 247, 272-273, 276, 278, 280, 282, 284, 289

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*****Group 2*****
315C L	CJC05492, 5508, 5522, 5531, 5534, 5538, 5542, 5547, 5565, 5570, 5574, 5578, 5581, 5587, 5592, 5605, 5607, 5610, 5613, 5615, 5620, 5629-5630, 5644, 5648, 5652, 5655, 5658, 5661, 5664-5665, 5669, 5677, 5680, 5685, 5687, 5690, 5698
315D LC	CJN00579, 581, 583, 586, 589, 591-592, 596-597, 599, 603-605, 608, 610, 612-613, 615, 618-619, 621-622, 624-626, 629, 632-635, 637-639, 642-645, 647, 650, 653-656, 658, 660, 663-665, 667, 669-671, 673, 675-676, 678, 680, 682, 684-687, 689-692, 694, 696, 698-699, 701, 703, 706-707, 709, 712, 714-715, 721-730, 732-733, 739, 741-743, 745, 748, 750-751, 757-761, 763-768, 770-771, 773, 775-776, 778-779, 782, 784, 789-794, 796-802, 804-805, 807-808, 810-812, 818-829, 834-835, 839-841, 843, 845, 847-848, 854-861, 863, 865, 867, 911, 914, 917-918, 922-923, 925-927, 929, 933, 935-936, 942, 944-945, 947, 949, 962, 1047, 1055-1056, 1059-1060, 1064-1066, 1069, 1071, 1073, 1078-1080, 1084-1086, 1090-1096, 1098-1100, 1105-1107, 1109-1111, 1113, 1116-1124, 1126-1136, 1150-1159, 1164-1168, 1173-1174, 1181, 1185-1186, 1190-1191, 1193, 1196-1197, 1201-1209, 1213-1217, 1219-1228, 1231, 1233, 1235, 1237-1249, 1254, 1258, 1261, 1263-1268, 1270-1284, 1288-1290, 1292-1298, 1300, 1303-1305, 1314-1318, 1320-1322, 1326, 1328-1333, 1336-1338, 1340, 1343-1345, 1347-1354, 1358-1359, 1362, 1364, 1370, 1372-1374, 1376-1377, 1379-1380, 1383-1384, 1386-1394, 1396-1398, 1400-1405, 1407-1412, 1417-1419, 1421, 1424, 1426, 1429, 1431-1436, 1438, 1442, 1445, 1448-1453, 1456-1458, 1460, 1462, 1465, 1468-1471, 1473, 1475-1476, 1484, 1488, 1491, 1499, 1503, 1508, 1510, 1513-1515, 1517-1518, 1520-1521, 1523, 1526-1527, 1529, 1531-1532, 1534-1535, 1537-1539, 1542-1546, 1548, 1551-1553, 1555, 1601, 1604, 1609-1614, 1618, 1649, 1657

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	PLATE	DEALER FABRICATED
The plate is Dealer Fabricated.
*****Group 2*****
1	3218130	PLATE AS
1	3325250	PLATE 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 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 the bucket fails, remove and repair the part where the crack occurs. 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*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 19.0-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*****
0-3000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 20.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

Introduction

This instruction contains the information for the repair/reinforcement of the failed bucket on certain 312C and 312D Excavators.
Do not perform any of the procedures until you have read the information in this publication.

Note 1:
Welding quality is critical to the success of the reinforcement procedures. Welds must be smooth and continuous. No overlap is allowed. Grind the ends of the welds to a smooth radius.

Prepare the metal for welding according to the next section. Refer to the illustrations in this Rework Procedure for welding symbols and specifications.

Use LB-26 Electrodes (AWS E7016 or AWS E7018) or equivalent electrodes to weld the baffle plate and reinforcement plates. 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 E71T-5 with negative polarity. The welding wire must be protected with CO2 or Argon/CO2 80/20 gas.

All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300?degC (572?degF). The electrodes must be dried for at least 30 minutes.

Do not weld in windy conditions. Do not weld when temperatures are below 16?degC (60?degF).

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.

Note 2:
Cover all finished bores and threads. Finished bores and threads must be protected from shot blasting, welding 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 any oil or grease that is on the bucket.
Remove paint, rust, dirt and scale with a wire brush or by buffing or grinding. Shot blasting all work areas can also remove foreign material.

The repair/reinforcement procedure that follows is applicable to the affected buckets that are listed in Table 1.

Image1.2.1

1. Preparation of the repair parts.
Fabricate two reinforcement plates (A) for the buckets that are used on 312C and 312D Excavators.
Refer to Illustration 1, Table 2 and Table 3 for the dimensions.

Image1.3.1

Image1.3.2

Image1.3.3

2. Repair procedure. Complete Steps 1 through 4.

Step 1: Grind or gouge out the cracked welds in the bucket. Refer to Illustrations 2 and 3.

Image1.4.1

Image1.4.2

Step 2: Make sure that the weld area for the reinforcement plate is clear. Refer to Illustration 4.

Image1.5.1

Step 3: Reweld the area that contained the crack.

Step 4: Reinforcement
Install the two reinforcement plates (A). Refer to Illustrations 5 through 7.

Image1.7.1

Image1.7.2

(EE) 10 mm (0.39 inch) at two places
(W1) Make an 8 mm (0.32 inch) fillet weld with 1.5 mm (0.06 inch) weld penetration at two places.

Image1.8.1

(EE) 10 mm (0.39 inch)
(HH) 9 mm (0.35 inch)
(W2) Make a 10 mm (0.39 inch) bevel groove weld at two places.
(W3) Make a 10 mm (0.39 inch) fillet weld over a bevel groove weld with 10 mm (0.39 inch) weld penetration at two places.

3. Apply a coating with corrosion resistance. Apply a paint finish.

Group Number 2

Introduction

This instruction contains the information for the repair of the failed bucket on certain 315C and 315D Excavators.

Refer to general note described in Group 1 introduction.

1. The repair procedure that follows is applicable to the affected buckets that are listed in Table 4.

Image2.2.1

2. Repair/reinforce procedure: Complete Steps 1 through 3.

Step 1: Grind out or gouge out the weld of the failed top assembly (shadowed part in Illustration 8) in the bucket.
The weld between the top assembly and the gusset should be removed carefully since it is used as a guide of re-assembling the new top assembly.
Refer to Illustration 8.

Image2.3.1

Step 2: After removing the top assembly, make sure that welding area removed is clean.

Step 3: Assemble the 321-8130 or 322-5250 Top Assembly to the bucket body. Properly set the position of top assembly, and do the spot weld. Refer to Table 5 and Illustration 9.

Image2.5.1

Image2.5.2

Step 4: Weld the top assembly according to Illustrations 10 and 11.

NOTE:
1. To do pre heat with min 150degC
2. Weld edge as shown in Illustration 11 Detail E require weld treatment. Grinding or TIG treatment.

Image2.6.1

Image2.6.2

(W1) Make an 8 mm (0.32 inch) fillet weld with 1.5mm (0.06 inch) weld penetration at two places.
(W2) Make a 10 mm (0.39 inch) fillet weld with 1.5mm (0.06 inch) weld penetration at two places.
(W3) Make a 6 mm (0.24 inch) fillet weld with 1.5mm (0.06 inch) weld penetration at two places.
(W4) Make a 8 mm (0.32 inch) beveled groove weld at two places
(W5) Make a 8mm (0.32 inch) fillet weld over a bevel groove weld with 8 mm (0.32 inch) weld penetration at two places.

3. Apply a coating with corrosion resistance. Apply a paint finish.