PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUNTERWEIGHT BOLTS ON CERTAIN 345C EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUNTERWEIGHT BOLTS ON CERTAIN 345C EXCAVATORS [REBE3617]

FRAME AND BODY

COUNTERWEIGHT GP

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUNTERWEIGHT BOLTS ON CERTAIN 345C EXCAVATORS

REBE3617-01

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03Apr2008

(Revised 01May2008)

U-166

A-133

O-150

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE COUNTERWEIGHT BOLTS ON CERTAIN 345C EXCAVATORS
7056		PI10670

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10670" 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 "PI10670" 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:	This Revised Service Letter replaces the 03Apr2008 Service Letter. Changes have been made to the Affected Product. Two machines have been added - PJW02346 and PJW2376.

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PROBLEM

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The existing counterweight bolts may fail unexpectedly with the potential to become high-energy projectiles. This type of bolt failure may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
345C	ESD00238, 240, 242-243 PJW02287, 2291, 2296, 2300-2301, 2303-2311, 2313, 2317-2325, 2330-2334, 2337-2339, 2341-2342, 2344-2347, 2355-2356, 2358-2367 TDG00400-00401, 403-405, 407
345C L	TAJ00338, 343, 346-362, 364-365, 368
345C MH FCR	M2R00221, 224

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*****Group 2*****
345C	ESD00241, 244 PJW02302, 2312, 2314-2316, 2326-2328, 2376 TDG00402

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	1277678	BOLT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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*****
6	1277678	BOLT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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The 127-7678 Counterweight Bolts need to be replaced on certain 345C Excavators. Refer to the attached Rework Procedure.

NOTE: Defective bolts were not distributed through the parts system so all dealer inventory is conforming and fit for use.

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OWNER NOTIFIAVSION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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AVSpare		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 4.0-hour job for Group 1
An additional 12 hours, plus material, will be allowed to fabricate barrier as described in rework procedure.

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AVSpare		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 4.0-hour job for Group 2
An additional 12 hours, plus material, will be allowed to fabricate barrier as described in rework procedure.

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PARTS DISPOSITION

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MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING COUNTERWEIGHT BOLTS

MODELS INVOLVED - 345C, 345C L, 345C FCR, 345C LC-FX, 345C LC-VG EXCAVATORS

Dear AVSpare Product Owner:

Certain machines need to be removed from service and have the counterweight mounting bolts replaced. The existing counterweight mounting bolts could fail unexpectedly and become high energy projectiles with the potential for serious injury or death. You will not be charged for the service performed.

Please contact your local AVSpare 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 03Apr2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

AVSpare Inc.

Identification #(s)

Attached to 03Apr2008 Service Letter

Rework Procedure

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Group Number 1

Rework procedure for CTWT mounting bolts replacement (Group 1: Standard CTWT)

To protect the serviceman and bystanders from a potential high-energy projectile, utilize a vertical barrier perpendicular to the counterweight bolts to cover the areas shown in Image 1.1.1. Locate the barrier in close proximity to the bolt (maximum distance of 250 mm) until the bolt preload (and energy) is removed. If a failure were to occur, the bolt will fracture in the threads, and require 500mm of travel before exiting the counterweight.

NOTE: The barrier could be fabricated from a steel plate or it could be the counterweight from another excavator. A properly positioned barrier will contain a fractured bolt within the counterweight. If necessary, the 259-6113 Counterweight Cover Plate, could be removed to position the barrier. However, serviceman should be clear of the counterweight bolts during removal.

1. Position the machine on a hard level surface. Lower the work tool to the ground.

2. Move the hydraulic lockout control to the LOCKED position.

3. Raise, or remove, the counterweight cover plate as shown in Image 1.1.1. Use the barrier plate or additional machine counterweight to cover the bolts in the area where the bolts are being removed.

Image1.1.1

4. Fasten a proper rated cable with shackles to the brackets in order to support the counterweight and relieve the weight on the counterweight mounting bolts. Refer to Image 1.2.1.

Image1.2.1

5. Replace the counterweight mounting bolts one at a time, per the sequence shown in Image 1.3.1.

Image1.3.1

6. Follow the procedure below to replace each counterweight mounting bolt:
a) Place reaction bar in the counterweight as shown in Image 1.4.1.

Image1.4.1

b) Place the torque multiplier and torque wrench combination and suspend with a nylon strap utilizing an appropriate lifting device as shown in Image 1.5.1. This strap will support the tool combination, hold the tools in place, and keep the serviceman out of the harms way.
c) Serviceman must stand on side of counterweight while loosing bolts. These bolts could break unexpectedly and become a high energy projectile.

Image1.5.1

d) Install bolt and washer. Tighten bolt to a torque of 2,700 +/- 300 Nm.

Group Number 2

Rework procedure for CTWT mounting bolts replacement (Group 2: CTWT removal system Installed)

To protect the serviceman and bystanders from a potential high-energy projectile, utilize a vertical barrier perpendicular to the counterweight bolts to cover the areas shown in Image 2.1.1. Locate the barrier in close proximity to the bolt (maximum distance of 250 mm) until the bolt preload (and energy) is removed. If a failure were to occur, the bolt will fracture in the threads, and require 500mm of travel before exiting the counterweight.

NOTE: The barrier could be fabricated from a steel plate or it could be the counterweight from another excavator. A properly positioned barrier will contain a fractured bolt within the counterweight. If necessary, the 259-6113 Counterweight Cover Plate, could be removed to position the barrier. However, serviceman should be clear of the counterweight bolts during removal.

1. Position the machine on a hard level surface. Lower the work tool to the ground.

2. Move the hydraulic lockout control to the LOCKED position.

3. Raise, or remove, the counterweight cover plate as shown in Image 2.1.1. Use the barrier plate or additional machine counterweight to cover the bolts in the area where the bolts are being removed.

Image2.1.1

4. Start the engine, adjust the engine speed to one-third of full throttle engine speed. Make sure that the hydraulic lockout control to the LOCKED position.

a) Open the rear access door on the right side of the machine.
b) Move switch (2) to the on position. Refer to Image 2.2.1.

Image2.2.1

c) Move both stop valves (1) to the OPEN position. Refer to Image 2.2.1.
d) Move control lever (3) upward in order to relieve the weight on the counterweight mounting bolts. There should be a slight tension on the chains. Refer to Image 2.3.1.

Image2.3.1

5. Replace counterweight mounting bolts in the sequence indicated in Image 2.4.1.

Image2.4.1

6. Follow the procedure below to replace each counterweight mounting bolts:
a) Place reaction bar in the counterweight as shown in Image 2.5.1.

Image2.5.1

b) Place the torque multiplier and torque wrench combination and suspend with a nylon strap utilizing an appropriate lifting device as shown in Image 2.6.1. This strap will support the tool combination, hold the tools in place, and keep the serviceman out of the harms way.
c) Serviceman must stand on side of counterweight while loosing bolts. These bolts could break unexpectedly and become a high energy projectile.