PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE THREAD DEPTH OF THE M16 MOUNTING HOLES IN THE MAIN CONTROL VALVE ON CERTAIN 320C, 320C L, 320C LU, AND 330C L HYDRAULIC EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE THREAD DEPTH OF THE M16 MOUNTING HOLES IN THE MAIN CONTROL VALVE ON CERTAIN 320C, 320C L, 320C LU, AND 330C L HYDRAULIC EXCAVATORS

Usage:

SEBE9450

January 10, 2006
U-16
D-16
O-16

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE THREAD DEPTH OF THE M16 MOUNTING HOLES IN THE MAIN CONTROL VALVE ON CERTAIN 320C, 320C L, 320C LU, AND 330C L HYDRAULIC EXCAVATORS
5051		PI30892

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30892" 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 "PI30892" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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COMPLETION DATE	TERMINATION DATE
July 31, 2006	January 31, 2007

PROBLEM

The M16 holes in the main control valve may not be threaded deep enough which prevents the mounting bolts from properly securing the main control valve to the upper frame on certain 320C, 320C L, 320C LU, and 330C L Hydraulic Excavators.

AFFECTED PRODUCT

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Model	Identification Number
320C	AMC4565, 4590, 4593, 4603 PAB3757, 3762, 3767, 3777, 3782, 3810, 3811, 3819
320C L	PAC728
330C L	KDD1091, 1097, 1098, 1103, 1112, 1119

PARTS NEEDED

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Qty	Part Number	Description
1	8T3096	TAP-HAND
4	9X8257	WASHER
4	1003866	BOLT

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

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%	8.0	0	0	0	0
NOTE: This is a 8.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE THREAD DEPTH OF THE M16 MOUNTING HOLES IN THE MAIN CONTROL VALVE

MODELS INVOLVED - 320C, 320C L, 320C LU, AND 330C L HYDRAULIC EXCAVATORS

Dear Caterpillar Product Owner:

The threaded holes in the main control valve may not be threaded deep enough. This will prevent the mounting bolts from properly securing the main control valve to the upper frame. 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 January 10, 2006 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 January 10, 2006 Service Letter

Rework Procedure

For 320C, 320C L, and 320C LU Excavators, refer to the Disassembly and Assembly Manual, RENR3826, for the 320C Excavator Machine Systems. For 330C L Excavators, refer to Disassembly and Assembly Manual, RENR5438, for the 330C Excavator Machine Systems. Review, understand, and adhere to all safety and environmental warnings and notices assaciated with accessing, inspecting, reworking, and returning this piece of equipment to customer use.

Remove the main control valve mounting bolts one at a time and inspect for damage to the threads.

NOTE: The following picture shows the damage caused to the bolt threads when the main control valve mounting hole thread depth is not deep enough.

If the thread does not show this damage, one at a time, install new 100-3866 M16 Bolts along with a new 9X-8257 Washer. Tighten the bolts to a torque of 240 Nm +/- 40 Nm. There are a total of 4 bolts and washers per machine. No further repair is needed.
If the bolt threads have been damaged, the holes need to be re-tapped. The depth of the drilled hole is correct, so rework will involve only cutting the bolt thread deeper. Rework each hole one at a time, re-tapping to a hole thread depth of 27mm. Use an 8T-3096 M16X2 D7 Plug Tap.

NOTE: The rework to the main control valve mounting hole thread depth can be performed in chassis. To gain additional access, draining and removing the hydraulic tank can be an option.

Clean the threaded hole thoroughly to remove chips, cutting fluid, or other debris. One at a time, install new 100-3866 M16 Bolts along with a new 9X-8257 Washer. Tighten the bolts to a torque of 240 Nm +/- 40 Nm. There are a total of 4 bolts and washers per machine. Replace machine components and fluids if necessary.