PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM AND THE STICK DRIFT REDUCTION VALVES INSIDE THE MAIN CONTROL VALVE ON CERTAIN 345C EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM AND THE STICK DRIFT REDUCTION VALVES INSIDE THE MAIN CONTROL VALVE ON CERTAIN 345C EXCAVATORS [REBE3050]

HYDRAULIC SYSTEM

VALVE GP-LOAD CONTROL

PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM AND THE STICK DRIFT REDUCTION VALVES INSIDE THE MAIN CONTROL VALVE ON CERTAIN 345C EXCAVATORS

REBE3050-01

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14Jan2008

(Revised 08Oct2009)

U-25

A-22

D-19

O-21

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM AND THE STICK DRIFT REDUCTION VALVES INSIDE THE MAIN CONTROL VALVE ON CERTAIN 345C EXCAVATORS
5147 5811		PS42601

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42601" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the 14Jan2008 Service Letter. Changes have been made to Rework Procedure.

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TERMINATION DATE

31Jan2010

PROBLEM

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The existing 096-3001 Setscrew could come out of the spool for the 270-5698 Valve Group-Pilot for the boom or stick function on certain 345C Excavators, causing excessive cylinder drift and/or reduce the speed of the boom-down or stick-in. The assembly process for the setscrew was improved. Replacement of 270-5698 Valve Group-Pilot solves the problem.

AFFECTED PRODUCT

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Model	Identification Number
345C	ESD00185, 192-200, 202-216, 218-233 GPH00139-00140, 147, 152, 158, 165, 169, 171-172, 174-175, 179, 181, 183-184, 187-188, 193, 196, 199, 204-205, 209-212, 214-216, 219-221, 224-225, 229, 231-235, 237-239, 241-255, 258-264, 266, 268-273, 275-295, 297-300, 302-303, 305-309, 311, 314-315, 318-329, 332-347, 349-350, 353, 356-364, 367-373, 375-378, 380-381, 383-388, 390-412 PJW00916, 919-920, 930, 932, 937, 939, 950, 952-953, 955, 962, 964, 969, 974, 978, 982, 984-985, 992-993, 1001, 1012, 1014, 1020, 1022, 1024-1028, 1031, 1037, 1044-1046, 1048, 1058, 1060-1061, 1063-1066, 1069-1070, 1074-1077, 1082-1083, 1090-1091, 1106, 1108, 1123, 1125, 1127-1128, 1134, 1136-1139, 1142-1144, 1149, 1151-1153, 1155, 1158, 1160, 1164, 1166-1169, 1171-1172, 1175, 1185-1187, 1195, 1197-1198, 1200, 1204-1205, 1211-1213, 1215, 1218, 1220, 1222-1223, 1229-1231, 1236, 1241-1242, 1244-1245, 1248-1250, 1252, 1254, 1256-1257, 1259, 1261-1264, 1269, 1271-1272, 1277-1278, 1280-1285, 1290-1293, 1295, 1299-1305, 1307-1311, 1314-1316, 1318-1320, 1322, 1324-1331, 1333, 1335-1336, 1339-1344, 1347-1355, 1357-1360, 1362-1367, 1370-1371, 1373-1375, 1378-1379, 1381-1397, 1399-1417, 1419-1437, 1439-1447, 1449-1454, 1456, 1460-1464, 1466-1474, 1476, 1478-1480, 1482-1491, 1493-1494, 1496-1501, 1503-1504, 1506-1515, 1517-1523, 1525-1526, 1528-1592, 1594, 1596-1634, 1636-1665, 1667-1683, 1685-1800, 1802-1839, 1841-2193 TDG00275, 280, 290-291, 293-294, 298, 300-325, 327-390
345C L	LYS00133, 136, 140, 147-148, 153, 156-157, 161, 163, 165-168, 170-176, 178-186 S5M00221-00223, 225-232, 234-285
345CL	ELS00170, 176 FPC00101, 104, 106, 108, 113, 126, 128, 130-139, 141-143, 145-146 GCL00239, 242, 245-246, 249, 254, 268, 270-276 TAJ00251, 254, 256-257, 264, 266, 268, 271-325

PARTS NEEDED

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Qty	Part Number	Description
6	3J1907	SEAL-O-RING
2	4J0520	SEAL-O-RING
2	4J0523	SEAL-O-RING
2	4J7533	SEAL-O-RING
2	5P3108	SEAL-O-RING
4	0951576	SEAL-O-RING
2	2705698	VALVE GP-BASIC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-2000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-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.

Rework Procedure

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Note: Machine equipped with Boom Lowering Check Valves do not have Boom drift reduction valve; items related to "Boom Drift Reduction Valve" are not applicable on those machines. For those machines only one of the two 270-5698 Valve Group-Pilot has to be ordered.

SAFETY OPERATIONS PRIOR TO STICK /OR BOOM DRIFT REDUCTION VALVE REWORK:

The release of hydraulic pressure in the hydraulic circuit is required before service is performed to the hydraulic circuit. Release the pressure in the hydraulic circuit before any hydraulic lines are disconnected or removed from the hydraulic circuit.

Note: Refer to the Disassembly and Assembly Manual for additional information concerning service of the components of specific hydraulic circuits.

WARNING
Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "AVSpare Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on AVSpare products. Dispose of all fluids according to local regulations and mandates.

Perform the following steps in order to release the hydraulic pressure from the desired hydraulic circuit of the main hydraulic system:
1) Place the machine on flat level ground.
2) Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground - See Image.
3) Stop the engine.
4) Release the pressure in the stick and boom down hydraulic circuits. Refer to RENR6690 Testing & Adjusting Section, "Hydraulic System Pressure - Release Of Hydraulic Pressure From A Single Hydraulic Circuit".

Image1.1.1

REMOVAL OF EACH STICK AND BOOM DRIFT REDUCTION VALVE FROM THE MAIN CONTROL VALVE:
1) Disconnect the 2 hydraulic lines from drift reduction valves.
2) Remove the 4 M16 bolts.
3) Pull by hand the drift reduction valves. If hydraulic pressures are properly released, the check valve part (Image 1.3.1; items 4 and 5) of the drift reduction valves will remain inside the main control valve and do not need to be removed.

Image1.2.1

Image1.2.2

REWORK OF THE DRIFT REDUCTION VALVES:

1) Open the valve by removal of the 2 M8 socket-head bolts.
2) Transfer all plugs, rings, stem-spring-retainer (4I-8965 Guide), and stem-spring from the 270-5698 Valve Group-Pilot (Image 1.3.1; item 8) to the new ones.

NOTE: It is required to transfer the 4I-8965 Guide (Item #2 in Image1.3.1) to the replacement valve group while performing this service letter.

Replace all seals with new ones:
4J7533 Seal detail of item 6
095-1576 Seal item 9
3J1907 Seal item 11
4J0520 Seal item 12
4J0523 Seal item 13
5P3108 Seal item 14
Tighten item 6 plugs to a torque of 10 +/-2 Nm.
Tighten item 1 plug to a torque of 34 +/-3 Nm.

3) Close the valve and tighten the two M8 socket-head bolts to a torque of 28 +/-7 Nm.

Image1.3.1

RE-ASSEMBLY OF THE DRIFT REDUCTION VALVES ON THE MAIN CONTROL VALVE:

1) Push by hand the drift reduction valves to the original position inside the main control valve .
2) Reassemble the 4 M16 bolts with 240+/-40 Nm.
3) Reconnect the 2 hydraulic lines to drift reduction valves.
4) Proceed with the appropriate paint touch-ups.
5) Start the engine.
6) Slowly move the joysticks to raise the boom and stick 1 meter off the ground and then lower it back down again. Repeat this operation 10 times to purge the air.?