PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND IF NECESSARY REWORKING THE UPPER FRAME ON CERTAIN M313D, M315D, M316D, AND M318D WHEELED EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND IF NECESSARY REWORKING THE UPPER FRAME ON CERTAIN M313D, M315D, M316D, AND M318D WHEELED EXCAVATORS

Usage:

REBE5351-00

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23Jul2009

U-270

D-234

O-241

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND IF NECESSARY REWORKING THE UPPER FRAME ON CERTAIN M313D, M315D, M316D, AND M318D WHEELED EXCAVATORS
7051 0679		PI31677

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31677" 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 "PI31677" 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:

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:

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COMPLETION DATE	TERMINATION DATE
31Jan2010	31Jul2010

PROBLEM

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The upper frame beam located directly below the cab needs to be inspected and possibly reworked on certain M313D, M315D, M316D, and M318D Wheeled Excavators. The existing weld may have been incorrectly completed, which can lead to failure in extreme conditions. If this weld should fail, the upper frame can bend, leading to a very long and costly repair.

AFFECTED PRODUCT

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Model	Identification Number
M313D	W3H00398-00471, 473-495
M315D	W5M00382-00470
M316D	W6A00732-00770, 772-775, 777-815
M318D	W8P00710-00835

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 0.5-hour job
If the frame must be reworked, an additional 4.5 hours labor and the costs for additional materials (paint, grinding tools, etc) up to a maximum of $100 US Dollars will be allowed.

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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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND IF NECESSARY REWORKING THE UPPER FRAME

MODELS INVOLVED - M313D, M315D, M316D, AND M318D WHEELED EXCAVATORS

Dear Caterpillar Product Owner:

The upper frame needs to be inspected and possibly reworked on the products listed below. The existing weld may have been incorrectly completed, which can lead to failure. 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 23Jul2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 23Jul2009 Service Letter

Rework Procedure

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Inspect the welds, and if necessary, rework according to this procedure.

Image1.1.1

Image1.1.2

Inspection Procedure:
1. Place the machine on level ground and lower the dozer blade and/or stabilizers (without raising the machine from the ground), and swing the machine 45? to the left.
2. Remove the panels below the cab with a large flat-headed screwdriver to gain access to the affected weld.
3. Inspect the inside of the profile. The weld penetration should fill the space between the profiles. If the penetration is less, then the gap should not be deeper than 1-2mm (1/25-2/25"). If the weld meets these criteria, then the rework does not have to be performed. Image 1.2.1 is an example of a non acceptable weld. Image 1.2.2 is an example of an acceptable weld.

Image1.2.1

Image1.2.2

4. If the weld does not meet the criteria, then the rework must be performed.

Rework Procedure:
Follow the Caterpillar guidelines for general welding procedures in Special Instruction, REHS1841. This rework can only be performed by a certified welder using the specified materials. Use 2.5mm (0.1") or 3.2mm (0.125") ANSI/AWS A5.1 E7018 electrodes, and set the current of the welding machine to 60-100A for the 2.5mm electrode or 90-140A for the 3.2mm electrode and fine tune as necessary.
1. Turn off the key switch and open the battery switch on the machine.
2. Remove the access steps from left side of the undercarriage.
3. Cut the cable ties attached to the profile under the cab and move the electrical harness and hoses out of the way.
4. Using a carbide grinding drill bit or a similar tool, remove the weld bead from the groove until the surface is flat (i.e. no recessions in the weld bead) with no paint remaining in the groove.

Image1.4.1

Image1.4.2

Image1.4.3

NOTE: If the weld needs to be ground deeper than 4mm, then the repair should be done in two steps: first the two vertical grooves should be ground and welded, then the horizontal weld.

Image1.5.1

5. Using a punch and hammer, check the weld for any air pockets or gaps below the surface.
6. Remove the paint from the surrounding area.
7. Shield the pilot hoses from the welding heat by using a wet piece of leather.
8. Weld the groove closed.

Image1.6.1

Image1.6.2

9. Grind down the sharp edges of the weld bead where they meet the profile and remove excessive weld material and splatter.

Image1.7.1

10. Repaint the beam once it has cooled down.

Image1.8.1

Image1.8.2

11. Remove the leather heat shield, reattach the pilot hoses and the electrical harness to their mounting points, and install the covers under the cab.
12. Mount the access steps.