PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 4350019 ROD ASSEMBLIES ON CERTAIN WS305 XD WELL STIMULATION PUMPS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 4350019 ROD ASSEMBLIES ON CERTAIN WS305 XD WELL STIMULATION PUMPS

Usage:

TEBE2639-01

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09Apr2015

(Revised 16Apr2015)

U-160

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 4350019 ROD ASSEMBLIES ON CERTAIN WS305 XD WELL STIMULATION PUMPS
6002		PI32474

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32474" 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 "PI32474" 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:	This Revised Service Letter replaces the 09Apr2015 Service Letter. A change has been made to the SMCS code.

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COMPLETION DATE	TERMINATION DATE
31Oct2015	30Apr2016

PROBLEM

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The stay rod assemblies need to be replaced on certain WS305 XD Well Stimulation Pumps. The existing 4350019 Rod Assemblies are .4 inches too short.

AFFECTED PRODUCT

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Model	Identification Number
WS305 XD	EA240635-40642, 40651, 41521-41529, 41579

PARTS NEEDED

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Qty	Part Number	Description
20	4350019	ROD AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Replace the existing 4350019 Rod Assemblies.
Refer to Disassembly and Assembly, UENR3290 for repair guidance.
Refer to the attached Rework Procedure.

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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 12.0-hour job

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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 REPLACING THE 4350019 ROD ASSEMBLIES

MODELS INVOLVED - CERTAIN WS305 XD WELL STIMULATION PUMPS

Dear Cat Product Owner:

The 4350019 Rod Assemblies need to be replaced on the products listed below. The existing 4350019 Rod Assemblies are .4 inches too short. 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 09Apr2015 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 09Apr2015 Service Letter

Rework Procedure

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Before completing the attached Rework Procedure, review the safety actions in the pump Operation and Maintenance Manual. If the pump is installed, read and understand the machinery operators manual for safety information and safe working practices before starting this Rework Procedure.

Stay Rod Installation Instructions

1.0 SCOPE
1.1 This instruction pertains to installation of the longer stay rod.

2.0 SPECIAL PREPARATIONS
2.1 Stay rods must always be replaced as a set.

3.0 INSTRUCTIONS
3.1 Before installation of the new stay rods, carefully clean thread bore and surrounding surface area on the power end nose plate.

3.2 Place Anti-Seize (Never-Seize or Copper Coat anti-seize) in the bottom 3/4" of the threaded bore on the power end nose plate.

3.3 Install stay rod stud and thread approximately 1-3/4" into the threaded bore.

3.4 Apply "Loctite" stud lock (red) to the last 3 to 4 threads of the stay rod stud.

3.5 Finish installation of the stay rod stud (2) until the overall exposed length dimension is obtained. 18.463" minimum to 18.525" maximum. Reference Dimension "Y" in Image 1.2.1.

Image1.2.1

3.6 Apply a liberal coating of grease (axle grease or equivalent) to the stay rod stud to prevent corrosion and possible premature failure.

3.7 Apply a thin coating of grease (axle grease or equivalent) inside the stay rod sleeve and install over the stay rod stud.

3.8 Repeat above steps for all the remaining stay rod assemblies

3.9 Position the fluid end on the stay rods and slide the fluid end onto the stay rods until it bottoms out on the stay rod shoulders.

3.10 Apply Anti-Seize (Never-Seize or Copper Coat anti-seize) on the 1-7/8" threads prior to installing the 1-7/8" retainer nuts.

3.11 Install the two outer-most heavy hex nuts on both sides and hand tighten. Screw all remaining heavy hex nuts in and hand tighten.

3.12 Using a hydraulic tensioning tool or torque wrench, tighten all hex nuts to 2700 ft-lbs using the sequence illustrated in Image1.3.1. The nuts MUST be kept tight. Under-torqued nuts will lead to thread fatigue failure of the stay rods.