PRODUCT IMPROVEMENT PROGRAM FOR REWORKING ALL INNER BOLTS MAINTAINING THE SWING GEAR BEARING ON THE CARBODY ON CERTAIN 390D EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING ALL INNER BOLTS MAINTAINING THE SWING GEAR BEARING ON THE CARBODY ON CERTAIN 390D EXCAVATORS

Usage:

TEBE0708-00

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17Apr2014

U-205

A-153

D-186

O-176

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING ALL INNER BOLTS MAINTAINING THE SWING GEAR BEARING ON THE CARBODY ON CERTAIN 390D EXCAVATORS
7063		PI32330

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32330" 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 "PI32330" 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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COMPLETION DATE	TERMINATION DATE
31Oct2014	30Apr2015

PROBLEM

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The existing inner swing gear bolts do not have a correct clamping load on certain 390D Excavators. These bolts need to be inspected, and if needed, replaced.

AFFECTED PRODUCT

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Model	Identification Number
385C FS	EAM00325-00332 MMA00294-00303
390D	BYP00128-00139 KCZ00168-00180
390D L	WAG00199-00252 WAP00377-00582 WBT00212-00301
390D L OEM	M1M00107-00110
390F L	MGF00151-00155

PARTS NEEDED

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Qty	Part Number	Description
74	1994502	BOLT-HEX HEAD
74	4531667	SPACER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 36% 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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It is recommended that TEBE0721, Service Letter, "PRODUCT SUPPORT PROGRAM FOR REWORKING ALL INNER BOLTS MAINTAINING THE SWING GEAR BEARING ON THE CARBODY ON CERTAIN 390D EXCAVATORS", be performed at the same time as this Rework Procedure.

Inspection for potential swing bearing movement on the carbody.
Two cases are possible:

a) No movement of the swing bearing on the carbody is present, apply this Rework Procedure.

b) When movement of the swing bearing on the carbody is present, apply the Rework Procedure from TEBE0721, Service Letter, "PRODUCT SUPPORT PROGRAM FOR REWORKING ALL INNER BOLTS MAINTAINING THE SWING GEAR BEARING ON THE CARBODY ON CERTAIN 390D EXCAVATORS".

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

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 24.0-hour job
In this 24.0 hour job, is integrated the inspection time of 1.5 hours.

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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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING ALL INNER BOLTS MAINTAINING THE SWING GEAR BEARING ON THE CARBODY

MODELS INVOLVED - CERTAIN 390D EXCAVATORS

Dear Cat Product Owner:

The existing inner swing gear bolts do not have a correct clamping load on the products listed below. These bolts need to be inspected, and if needed, replaced. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 17Apr2014 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 17Apr2014 Service Letter

Rework Procedure

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INSPECTION PROCEDURE:

1. Park the machine on a smooth and level surface.

2. Check the eventual swing bearing sliding on the carbody by making a mark between the swing bearing and the carbody. Refer to Image1.1.1.

Image1.1.1

3. Activate the swing control lever with the dial engine speed at position "10", having made around a 180 degree turn, counter swing in the opposite direction to stop.

4. Check the mark.

a) If the mark is no more aligned, apply TEBE0721, Service Letter, "PRODUCT SUPPORT PROGRAM FOR REWORKING ALL INNER BOLTS MAINTAINING THE SWING GEAR BEARING ON THE CARBODY ON CERTAIN 390D EXCAVATORS".

b) If the mark is aligned, apply the following Rework Procedure.

REWORK PROCEDURE:

5. Remove the inspection cover that is located inside the battery box. Refer to Image1.3.1.

Image1.3.1

6. Align the bolt head with the center inspection hole.

7. Stop the engine and lock the hydraulic lockout control.

8. Clean the bolt heads.

9. Refer to Image1.4.1 in order to identify the 199-4502 Bolt type installed on the machine.

Image1.4.1

10. Inspect the bolts types below:

- If the bolts are Type 1, work is complete, there is nothing more to do.
- If the bolts are Type 2, complete Steps 11 to 17.
- If the bolts are Type 3, complete Steps 18 to 21.

11. For Type 2 bolts, first check the static torque of the bolts in the critical area. Refer to Image1.6.1.

To easily identify the starting bolt, mark the first bolt with a "1", the machine must be positioned with the boom in the front direction.

12. Use a clic torque wrench and set it at 1600 N.m. Check the bolts in the following range: 11 to 14, 24 to 27, 49, 50, 62, 63.

Image1.6.1

13. If all critical bolts are OK, for the other bolts located outside the critical area, check the static torque with the clic torque wrench set at 1600 N.m.
If one bolt is NOT OK, replace it by a new 199-4502 Bolt and new 453-1667 Spacer. Only bolts Type 1 and Type 2 are allowed for this Rework Procedure. Refer back to Image1.4.1.

14. If one bolt in the critical area is turning before reaching 1600 N.m, all bolts and spacers must be replaced by new 199-4502 Bolts Type 1 or Type 2 and new 453-1667 Spacers.

15. Before installation of the new components, degreasing of the components could be needed to clean bolts, spacers, and the area where the spacers seat on the swing bearing. Use a suitable solvent or degreaser.

16. Once dry, apply 5P-3931 Antiseize on bolt thread portion.

17. Tighten the bolt to specified pre-torque of 450 +/- 50 N.m and apply an angle of 90 degrees +/- 5.

18. Type 3 bolts bolts must be replaced one at a time by the new 199-4502 Bolts Type 1 or Type 2 and the new 453-1667 Spacers.

19. To reinstall the components, complete Steps 15 to 17.

20. Install the inspection cover with its gasket , the eight bolts must be installed with Loctite 242 on the threads and tightened to a specified torque of 20 N.m.

21. Pay attention. During this Rework Procedure, it is important not to have contacts between the tooling and battery cables in order not to create damage on the sheath. If a machine is equipped with the "Cold Weather" attachment, the additional battery cable will have to be rerouted in order to have good access to the bolts and avoid contact between the tooling and the cables.