PRODUCT SUPPORT PROGRAM FOR REPLACING THE BOOM GROUP ON CERTAIN 324D, 324DL, 329D, 329DL, 336D, 336DL, AND 340DL EXCAVATORS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REPLACING THE BOOM GROUP ON CERTAIN 324D, 324DL, 329D, 329DL, 336D, 336DL, AND 340DL EXCAVATORS

Usage:

TEBE0611-01

07Nov2013
(Revised 25Apr2014)


U-546
A-379
D-451
O-457

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BOOM GROUP ON CERTAIN 324D, 324DL, 329D, 329DL, 336D, 336DL, AND 340DL EXCAVATORS

6501
PS52556
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 "PS52556" 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.

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.

 
NOTE:

This Revised Service Letter replaces the 07Nov2013 Service Letter. Changes have been made to the Service Claim Allowances and Rework Procedure.


TERMINATION DATE

30Nov2015

PROBLEM

The existing boom may experience a crack in the rear baffle area on certain 324D, 324DL, 329D, 329DL, 336D, 336DL, and 340DL Excavators. If the crack is not detected early, it can extend to both side plates and possibly cause further cracks along the side plates.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
324D L  TSN00486-00520, 544-545, 550-552, 557-560, 564-566, 571-573, 578-579, 588, 597
*******Group  2*******
336D  JBT01209, 1350, 1363, 1392, 1422, 1483, 1485, 1490, 1497, 1575, 1579-1580, 1594, 1597, 1645, 1695, 1704-1707, 1710, 1716, 1718, 1721, 1724, 1743, 1755, 1762-1764, 1773, 1775, 1781-1782, 1784-1785, 1787-1788, 1794-1796, 1800-1801, 1806, 1809, 1814, 1820, 1828-1839, 1843, 1858-1875, 1879, 1881-1891, 1896-1899, 1910-1915, 1921, 1923, 1925-1936, 1939-1944, 1946-4754, 4756, 4758, 4760-4777, 4785-4790
336D L  MPL00399-00400, 405-406, 414-537, 542-546, 549-552, 554-559, 561-565
340D L  JTN00130-00131, 135-140, 148-155, 160-166, 173-185, 196-197, 200-213, 224-225, 228-239, 250-251, 255-256, 259-270, 280, 282, 285-286, 289-301, 312-313, 317-318, 321-358, 389, 396-397, 400-403, 411-412, 416-429, 445-467, 482-485, 493-510, 523-526, 534-551, 564-567
*******Group  3*******
329D  BYS00882, 993, 1000, 1015, 1023, 1027, 1031-1033, 1036, 1039, 1042, 1045, 1048-1050, 1054-1055, 1057-1065, 1067, 1070-1072, 1074, 1076-2613, 2634
329D L  DJF00301-00480, 488-492, 505-507, 556-565, 602-611, 629-664, 667-682, 684-703, 710-729, 742-772, 788-797, 813-817, 819, 821, 823, 825, 827, 829, 831
*******Group  4*******
324D  JZR00357, 535, 544, 546, 550-551, 564, 567-570, 575-1467
324D L  TSN00236-00237, 245-246, 250, 252-254, 258-410, 460-485, 521-543, 546-549, 553-556, 561-563, 567-570, 574-577, 580-587, 589-596, 598-608
*******Group  5*******
329D L  DJF00481-00487, 493-504, 508-555, 566-601, 612-628, 665-666, 683, 704-709, 730-741, 773-787, 798-812, 837-840
*******Group  6*******
336D L  MPL00538-00541, 547-548, 553, 560
340D L  JTN00132-00134, 141-147, 156-159, 167-172, 186-195, 198-199, 214-223, 226-227, 240-249, 252-254, 257-258, 271-279, 281, 283-284, 287-288, 302-311, 314-316, 319-320, 359-388, 390-395, 398-399, 404-410, 413-415, 430-444, 468-481, 486-492, 511-522, 527-533, 552-563, 568-572

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 2909240 BOOM AS-BRG &
2 PLATE1 Dealer Fabricated Part
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.

*******Group 2*******
1 4213469 BOOM AS-BRG &
2 PLATE5 Dealer Fabricated Part
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.

*******Group 3*******
1 3988947 BOOM AS-BRG &
2 PLATE4 Dealer Fabricated Part
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.

*******Group 4*******
1 3986990 BOOM AS-BRG &
2 PLATE2 Dealer Fabricated Part
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.

*******Group 5*******
1 2909267 BOOM AS-BRG &
2 PLATE3 Dealer Fabricated Part
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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.

*******Group 6*******
1 4270041 BOOM AS-BRG &
2 PLATE6 Dealer Fabricated Part
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

324D Machines - For operation hours less than 3500 hours, if cracking occurs, replace the boom group with a new boom group.

For operation hours beyond 3500Hrs on 324D machines, if boom group cracking occurs, the welding should be repaired according to the following Rework Procedure.

329D Machines - For operation hours less than 4000 hours, if cracking occurs, replace the boom group with a new boom group.

For operation hours beyond 4000 hours on 329D machines, if boom group cracking occurs, the welding should be repaired according to the following Rework Procedure.

336D and 340D Machines - For operation hours less than 4500Hrs, if cracking occurs, replace the boom group with a new boom group.

For operation hours beyond 4500Hrs on 336D and 340D machines, if boom group cracking occurs, the welding should be repaired according to the following Rework Procedure.

IMPORTANT: If the boom is replaced or repaired, please attach pictures of the failed boom including boom serial number, actual operation hours, and the cracking position when submitting the warranty claim.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-3500 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
3501-5000 hrs,
25-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
5001-8000 hrs,
37-48 mo 
100.0%
50.0%
0.0%
0.0%
0.0%
50.0%
 NOTE: This is a 16.0-hour job for Group 1
NOTE: For machines with less than 3500 hours, 16.0 hours is allowed for replacement of the boom.

NOTE: For machine operation hours more than 3500 hours, a new boom is NOT allowed, the boom should be repaired according to the Rework Procedure.

NOTE: An additional 44.0 hours of labor will be allowed if the boom is repaired according to the Rework Procedure.

NOTE: If the boom is replaced or repaired, please attach pictures of the failed boom including boom serial number, actual operation hours, and the cracking position when submitting the warranty claim.

NOTE: 100 US Dollars will be allowed for fabrication of the plate by dealer.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-4500 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
4501-7000 hrs,
25-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
7001-10000 hrs,
37-48 mo 
100.0%
50.0%
0.0%
0.0%
0.0%
50.0%
 NOTE: This is a 16.0-hour job for Group 2
NOTE: For machines with less than 4500 hours, 16.0 hours is allowed for replacement of the boom.

NOTE: For machine operation hours more than 4500 hours, a new boom is NOT allowed, the boom should be repaired according to the Rework Procedure.

NOTE: An additional 44.0 hours of labor will be allowed if the boom is repaired according to the Rework Procedure.

NOTE: If the boom is replaced or repaired, please attach pictures of the failed boom including boom serial number, actual operation hours, and the cracking position when submitting the warranty claim.

NOTE: 100 US Dollars will be allowed for fabrication of the plate by dealer.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-4000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
4001-6000 hrs,
25-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs,
37-48 mo 
100.0%
50.0%
0.0%
0.0%
0.0%
50.0%
 NOTE: This is a 16.0-hour job for Group 3
NOTE: For machines with less than 4000 hours, 16.0 hours is allowed for replacement of the boom.

NOTE: For machine operation hours more than 4000 hours, a new boom is NOT allowed, the boom should be repaired according to the Rework Procedure.

NOTE: An additional 44.0 hours of labor will be allowed if the boom is repaired according to the Rework Procedure.

NOTE: If the boom is replaced or repaired, please attach pictures of the failed boom including boom serial number, actual operation hours, and the cracking position when submitting the warranty claim.

NOTE: 100 US Dollars will be allowed for fabrication of the plate by dealer.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-3500 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
3501-5000 hrs,
25-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
5001-7000 hrs,
37-48 mo 
100.0%
50.0%
0.0%
0.0%
0.0%
50.0%
 NOTE: This is a 16.0-hour job for Group 4
NOTE: For machines with less than 3500 hours, 16.0 hours is allowed for replacement of the boom.

NOTE: For machine operation hours more than 3500 hours, a new boom is NOT allowed, the boom should be repaired according to the Rework Procedure.

NOTE: An additional 44.0 hours of labor will be allowed if the boom is repaired according to the Rework Procedure.

NOTE: If the boom is replaced or repaired, please attach pictures of the failed boom including boom serial number, actual operation hours, and the cracking position when submitting the warranty claim.

NOTE: 100 US Dollars will be allowed for fabrication of the plate by dealer.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 5*******
0-4000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
4001-6000 hrs,
25-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs,
37-48 mo 
100.0%
50.0%
0.0%
0.0%
0.0%
50.0%
 NOTE: This is a 16.0-hour job for Group 5
NOTE: For machines with less than 4000 hours, 16.0 hours is allowed for replacement of the boom.

NOTE: For machine operation hours more than 4000 hours, a new boom is NOT allowed, the boom should be repaired according to the Rework Procedure.

NOTE: An additional 44.0 hours of labor will be allowed if the boom is repaired according to the Rework Procedure.

NOTE: If the boom is replaced or repaired, please attach pictures of the failed boom including boom serial number, actual operation hours, and the cracking position when submitting the warranty claim.

NOTE: 100 US Dollars will be allowed for fabrication of the plate by dealer.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 6*******
0-4500 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
4501-7000 hrs,
25-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
7001-10000 hrs,
37-48 mo 
100.0%
50.0%
0.0%
0.0%
0.0%
50.0%
 NOTE: This is a 16.0-hour job for Group 6
NOTE: For machines with less than 4500 hours, 16.0 hours is allowed for replacement of the boom.

NOTE: For machine operation hours more than 4500 hours, a new boom is NOT allowed, the boom should be repaired according to the Rework Procedure.

NOTE: An additional 44.0 hours of labor will be allowed if the boom is repaired according to the Rework Procedure.

NOTE: If the boom is replaced or repaired, please attach pictures of the failed boom including boom serial number, actual operation hours, and the cracking position when submitting the warranty claim.

NOTE: 100 US Dollars will be allowed for fabrication of the plate by dealer.



PARTS DISPOSITION

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


Rework Procedure


 
General Rework Procedure for the Repair of Cracks at the Rear Baffle Plate of Boom

Refer to RENR8646, Disassembly and Assembly, the removal and installation procedure for the boom group, for 324D and 329D Machines.

Refer to RENR8648, Disassembly and Assembly, the removal and installation procedure for the boom group, for 336D and 340D Machines.

Refer to REHS1841, General Welding Procedures for Welding Requirements, Preparing the Metal for Welding, and Preparing the Machine for Servicing.

Refer to Image1.1.1 for boom weight information.
Image1.1.1
 
1. Use dye penetrant to inspect the entire area for possible cracks.

2. Use an air carbon arc torch in order to completely gouge out the crack including the inside of fillet weld. The gap must be a minimum of 3mm and should be large enough to install the backup strip. Refer to Images1.2.1 and 1.2.2.
Image1.2.1
Image1.2.2
 
3. Use a grinder in order to form 25 to 30 degree bevel on the edges of the side plate to form a good weld surface and to ensure weld penetration, and then insert the plate as backup strip. Refer to Image1.3.1.
Image1.3.1
 
Note A: The backup strip is to be made of mild steel, the thickness is 3mm, and the width is enough to cover the gap made in the side plate of the boom.

Note B: Tack weld wire to the backup strip. Tack weld the backup strip to the side plate and baffle plate and then remove the wire from the backup strip.

Note C: Do not tack weld the backup strip within 50mm (2.0 inch) from the ends of the gouge.

Note D: No crack welding is permitted on track weld beads.

4. Finish the weld. Make additional weld passes in order to fill the groove.
 
Note: After each weld pass, grind the weld smooth to form a good weld surface and to ensure weld penetration.

5. Grind any convex welds smooth. Add the recommended reinforcement plates refer to following procedure for the Addition of Reinforcement Plates

6. Relieve the stress in all welds by needle peening. A wire brush can be used to clean the welded area.

7. Use Cat authorized paint for painting the welds.
 
Procedure for the Addition of Reinforcement Plates:

The following Rework Procedure describes the details for the addition of reinforcement plates on the rear baffle plate. Ensure that the cracks in these areas have been repaired before completing the following procedure.

1. Fabricate a reinforcement plate that can be used on both sides of the boom. Refer to Image1.6.1 for 324D Reach Boom (5.9m). Refer to Image1.6.2 for 329D Reach Boom (6.15m).

Note: The reinforcement plate must be fabricated from ASTM A572 Grade 42 or Grade 50 steel, or the equivalent steel with a minimum yield strength of 290 MPa.
Image1.6.1
Image1.6.2
 
2. Ensure that the existing welds are ground smooth and flush before tack welding the plates. Refer to Image1.7.1.
Image1.7.1
 
3. Tack weld the reinforcement plates with a maximum gap of 1mm between the reinforcement plates and the base plates. Refer to Image1.8.1.

Note: Welding is made to extend and it is made to connect smoothly. All surfaces of welding should be grinded to remove weld pass notch as smooth surface.
Image1.8.1
 
4. Grind the finished surface of the welds. Use a brush or an air gun to remove any water, oil, dust, or any weld splatter.

5. Apply primer paint for corrosion control. Apply touch-up paint on the area with the repaired welds.

For 336D, 336DL, and 340DL Addition of Reinforcement Plates:

Refer to REHS5675, Special Instruction, "Procedures for the Repair of Cracks in Mass Booms and Heavy Duty Booms for Certain 330D and 336D Excavators", for 336D Mass Boom (6.18m).

Refer to REHS4595, Special Instruction, "Procedures for the Repair of Cracks in Reach Booms", for 336D Heavy Duty Reach Boom (6.5m).
 
 

Caterpillar Information System:

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