PRODUCT IMPROVEMENT PROGRAM FOR REPLACING BOLTS ON CERTAIN 301.5, 301.6, 301.8, AND 302.5 MINI HYDRAULIC EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING BOLTS ON CERTAIN 301.5, 301.6, 301.8, AND 302.5 MINI HYDRAULIC EXCAVATORS

Usage:

SEBE9295

August 8, 2005
O-217

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING BOLTS ON CERTAIN 301.5, 301.6, 301.8, AND 302.5 MINI HYDRAULIC EXCAVATORS
4177 4170 5057 5051 6052 5258 7451		PI10406

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10406" 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 "PI10406" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

8T-4136 Bolts need to be replaced on certain 301.5, 301.6, 301.8, and 302.5 Mini Hydraulic Excavators. These bolts may have been manufactured incorrectly and installed on the machines during assembly.

AFFECTED PRODUCT

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Model	Identification Number
****************************Group 1*************************
301.5	3YW5026, 5045, 5051, 5052, 5054-5058, 5060, 5062
301.6	BDH1322-1330, 1333-1337
****************************Group 2*************************
301.8	BFA4254, 4255, 4257-4267, 4270-4280, 4282-4286, 4289
****************************Group 3*************************
302.5	4AZ7422, 7423, 7426-7429, 7431, 7434, 7444
****************************Group 4*************************
302.5	4AZ7387, 7388, 7390-7393, 7401, 7403-7407, 7417, 7419

PARTS NEEDED

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Qty	Part Number	Description
*****************Group 1***************
5	8T-4136	BOLTS
*****************Group 2***************
7	8T-4136	BOLTS
***********Group 3 and Group 4*********
29	8T-4136	BOLTS

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

*Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	3.5	0	0	0	0
NOTE: This is a 3.5-hour job.

*****************************Group 2****************************

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	4.0	0	0	0	0
NOTE: This is a 4.0-hour job.

*****************************Group 3****************************

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	5.5	0	0	0	0
NOTE: This is a 5.5-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-Owner Notification)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING BOLTS

MODELS INVOLVED - 301.5, 301.6, 301.8, AND 302.5 MINI HYDRAULIC EXCAVATORS

Dear Caterpillar Product Owner:

New bolts need to be installed on the products listed below. If these bolts fail, the operator may lose control of the machine, possibly causing personal injury or death to the operator or bystanders. 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 August 8, 2005 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 August 8, 2005 Service Letter

Rework Procedure

In the following procedures, all of the 8T-4136 Bolts that are referenced must be inspected. Bolts that are found to have the letters "NL" stamped on the head, must be removed and discarded. Install new 8T-4136 Bolts and tighten the new bolts to a torque of 55 +/- 10 Nm.

Destroy all bolts that are removed from the machine in a way that prevents them from being used again.

Rework Procedure for the 301.5, 301.6, and 301.8

Remove the floor mat and the floor plate.
Remove the 139-4333 Cover Assembly (part of 145-4215 Upper Frame Group) that covers the 144-5983 Bank Valve Group (part of 145-4249 Bank Valve and Mounting Group).
Refer to Illustration 1. Inspect the two 8T-4136 Bolts that secure the 152-1932 Implement Linkage Group.
Remove the 096-6332 Knob and the 096-6333 Knob (parts of 150-3607 (Mounting and Control Group), the 148-5182 and 148-5184 Pedal Assemblies (if equipped) (parts of 148-5165 Speed and Direction Pedal Group) and the two 120-8840 Boots (rubber).
Disconnect the 153-3692 Pedal Assembly and the 139-4863 Pedal Assembly (parts of 152-5367 Boom Swing and Auxiliary Pedal Group) from their respective linkages. These are the pedals for the auxiliary hydraulics and the boom swing functions.
Remove the 153-3465 Plate Assembly (part of 152-5367 Boom Swing and Auxiliary Pedal Group).
Loosen the five fasteners that secure the 153-3639 Plate Assembly.
Remove the bolts that secure the 146-6335 Cab Heater Group (if equipped), remove the 146-6889 Filter Assembly (part of 147-3314 Cab Air Filter Group) from behind the heater and turn the heater through 90 degrees.
Completely remove the 153-3639 Plate Assembly (loosened in Step 7).

10) Refer to Illustration 2. Inspect the two 8T-4136 Bolts that secure the 163-9086 Bracket (part of 152-6618 Mounting and Control Group).

11) Refer to Illustration 2. Inspect the 8T-4136 Bolt that secures the 139-4853 Link Assembly (part of 152-6618 Mounting and Control Group).

12) Refer to Illustration 3. On 301.8 machines only, inspect the two 8T-4136 Bolts that secure the 237-9556 Bracket (part of 234-7631 Swing Motor Lines Group).

13) This completes bolt inspection. You must have inspected 5 bolts on 301.5 and 301.6 models and 7 bolts on 301.8 models. Bolts with the letters "NL" on the head must be discarded and replaced with new bolts.

14) Assemble all parts previously removed.

Illustration 1

145-4249 Mounting and Valve Group

Illustration 2

150-3607 Mounting and Control Group

Illustration 3

234-7631 Swing Motor and Lines Group.

Rework for the 302.5

Remove the 140-4128 Cover (part of 154-2593 Frame Group ? Upper) that covers the battery.
Refer to Illustration 4. Remove the 154-6283 Cover for the tank (part of 154-2679 Cover Group) and inspect the 8T-4136 Bolt indicated.
Refer to Illustration 5. Remove the 200-8607 Protector (part of 154-2679 Cover Group). Inspect the 8T-4136 Bolt that secures the bottom edge of the 195-1812 Cover.
Inspect the 8T-4136 Bolt that secures the 140-3880 Angle.
Inspect the four 8T-4136 Bolts that secure the 226-1352 Support Assembly.
Refer to Illustration 6. Remove the 200-8606 Protector (part of 154-2678 Cover Group).
Inspect the two 8T-4136 Bolts that secure the bottom edge of the 195-1811 Cover.
Inspect the four 8T-4136 Bolts that secure the 215-5074 Support Assembly.
Refer to Illustration 7. Remove the 140-3735 Cover and inspect the two 8T-4136 Bolts that secure the 4D-6466 Clips for 5P-9770 Hose and 5P-1420 Hose (parts of 154-2600 Lines and Fuel Filter Group).

10) If the machine is equipped with a cab, remove the cab. 11) Refer to Illustration 8. Inspect the two 8T-4136 Bolts that secure the floor plate (parts of 154-2606 Platform Group).

12) Refer to Illustration 9. Open the toolbox door and inspect the four 8T-4136 Bolts that secure the 159-7428 Support Assembly (part of 208-5093 Seat Support Group). Two of the bolts must be viewed from above.

13) Refer to Illustration 10. Inspect the four 8T-4136 Bolts that secure the 157-4768 Plate Assembly (part of 154-2606 Platform Group). Two of the bolts can be viewed from the toolbox opening. The other two must be viewed from the rear of the machine.

14) Refer to Illustration 11. Inspect the four 8T-4136 Bolts indicated (parts of 154-2606 Platform Group). Two of the bolts can be viewed from the toolbox opening. The other two must be viewed from above.

15) This completes bolt inspection. You must have inspected 29 bolts. Bolts with the letters "NL" on the head must be discarded and replaced with new bolts.

16) Assemble all parts previously removed.