PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CONTROL VALVES ON CERTAIN 323D, 324D, 325D, 330D AND 345C EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CONTROL VALVES ON CERTAIN 323D, 324D, 325D, 330D AND 345C EXCAVATORS [REBE3945]

HYDRAULIC SYSTEM

VALVE GP-LOAD CONTROL

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CONTROL VALVES ON CERTAIN 323D, 324D, 325D, 330D AND 345C EXCAVATORS

REBE3945-00

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04Aug2008

U-401

A-326

O-365

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CONTROL VALVES ON CERTAIN 323D, 324D, 325D, 330D AND 345C EXCAVATORS
5147 5811 5117 5067		PI10704

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10704" 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 "PI10704" 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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PROBLEM

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Certain Boom Lowering Control Valves (BLCVs) part number 225-4785 (for the 323D to 325D), 263-1962 (for the 330D), and 263-1964 (for the 345C) need to be reworked. Orifices in the existing valve can loosen, leading to incorrect operation of the BLCVs and in the event of a balancing line failure, an uncontrolled drop of front parts. This failure may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
323D L	BYM00237, 239, 241, 243-246, 248-250, 253-259, 263-264, 266, 268, 275-276, 278, 284, 287-288, 290, 293, 296, 299, 301-302, 304, 308-309, 311-314, 316, 318, 320, 322-325, 327-331, 335-336, 340, 343-351, 353, 363, 365, 368-369, 374, 391-392, 395, 402, 405, 410-416, 418-422, 424-425, 427, 430-432, 434-439, 441-443, 445-455, 466, 468, 472, 474-475, 479, 492, 500, 502, 510, 517-523, 525-530, 532-533, 535, 537-544, 546, 548-560, 562-570, 573-575, 577-590, 592-595, 597-602, 604-605, 607, 610-613, 615-621, 625, 627, 629-631, 633 JLG00352, 355-362, 370-372, 374-391, 393, 395-396, 398-399, 401-406, 409-410, 412-441
323D LN	RAC00311-00326, 328-329, 331-341, 343-351, 353-355, 357-364, 366, 368, 370, 372, 375-387, 389, 393, 395-401, 404-406, 408-409, 412-429, 432-433, 436-440, 442-446, 448-463, 465-467, 469-473, 475-478, 481, 483-485, 489-490, 492-497, 500, 503, 510
323D SA	SED00260-00336, 338-350, 352-353, 355-362, 364
324D L	SYM00638-00639, 641-644, 646-652, 655-659, 661, 669, 672-673, 675, 678-689, 691-693, 696, 698, 700, 703-705, 708-721, 725-728, 730, 732-741, 743-750 T2D00360-00361
324D LN	EJC00660-00661, 663-688, 690-700, 703-713, 715-729, 731-737, 739-757, 759-782, 784-786, 788-798, 800-814
325D	GBR00161-00163 GPB00835-00845, 850-852, 855-857, 870-885, 887-894, 896-899, 902-909, 911, 917-918, 920-925, 929-943, 945-947, 949-953, 955-959, 962, 966, 970-980, 982-991, 993-1011, 1016-1045, 1049-1051, 1056-1058 PKE00849-00869, 871-878, 880-900, 903, 906-918, 921-923, 925-962, 965-967, 970-981, 983-988, 990-998, 1000-1093, 1095-1101, 1103-1114, 1116-1126, 1128
325D L	LAL00312 MCL00204-00221
330D	ERN00320, 322-325, 327-330, 334-335, 342, 344-350, 352-353, 355-362, 364-366 GGE00665, 668-674, 676-680, 682-683, 685-689, 692-695, 698-700, 702-749, 751-754, 756-760, 762-778, 780-790, 792-793, 795-807, 811-860 RAS00961-00972, 974-984, 986-987, 989-991, 1001-1003, 1005-1013, 1016-1018, 1021, 1026, 1028-1029, 1033-1038, 1041-1054, 1056-1058, 1061-1070, 1073-1074, 1078-1087, 1094-1102, 1104-1132, 1134-1142, 1147-1154, 1157-1160, 1162-1164, 1169, 1173, 1177-1180, 1182, 1185-1188, 1190-1191, 1193-1197, 1199-1206 THJ00308-00331
330D L	LRM00386, 417-418
345C	GPH00400, 405-407, 409-413, 416, 419, 421-427, 429-431, 433-434, 436-437, 440-451, 453, 455-460, 462-468, 471-473, 475, 478-490, 492-499, 501-505, 507-508 SPC00266-00273, 275-276
345C L	LYS00187
345C MH HCR	MTE00131-00132
345D L	RGG00104-00105
M325D L MH	KAY00257-00263 KGG00246-00253
M325D MH	EDF00275-00282

PARTS NEEDED

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Qty	Part Number	Description
6	3J7354	SEAL-O-RING
6	8J6815	PLUG-ORIFICE
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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Refer to the attached Rework Procedure.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CONTROL VALVES

MODELS INVOLVED - 320D, 323D, 324D, 325D, 330D AND 345C EXCAVATORS

Dear AVSpare Product Owner:

The boom lowering control valves needs to be reworked on the products listed below. The existing valves can experience internal parts loosening involving incorrect operation. Failure may result in personal injury or death. You will not be charged for the service performed.

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 04Aug2008 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 04Aug2008 Service Letter

Rework Procedure

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Before starting the rework, secure the machine:
- Position the machine on level ground.
- 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.
- Shut off the engine.
- Turn the engine start switch to the ON position without starting the engine.
- Place the hydraulic activation control lever in the UNLOCKED position.
- Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL STROKE positions. This will release the high pressure only in that single hydraulic circuit.
This will also release any pressure that might be present in the pilot hydraulic circuit.
- Place the hydraulic activation control lever in the LOCKED position.
- Turn the engine start switch to the OFF position.
- Slowly loosen the filler plug on the hydraulic tank and release the pressure from the hydraulic tank. Leave the filler plug loose for a minimum of 45 seconds. This will release the pressure that may be present in the return hydraulic circuit.
- Tighten the filler plug on the hydraulic tank to the specified torque.
- The pressure in the single hydraulic circuit that requires service is now released and lines and components can be disconnected or removed from that hydraulic circuit.

Tighten the emergency boom lowering valve on the 323D to 325D Excavators only:
Position the bucket on the ground.
Loosen locknut (1) of the boom lowering check valve.
Tighten seat (2) clockwise to 2.25 +/-0.25 N.m.
Tighten locknut (1) to 4.0 +/-0.5 N.m.
Perform same procedure for second BLCV.

Image1.2.1

Image 1.2.1: 225-4785 or 263-1962 or 263-1964 Valve Group
1: 7Y-5226 Nut (323D to 325D only)
2: 165-9513 Seat (323D to 325D only)
3: 225-4820 Plug Assembly
4: 114-8229 Plug Orifice
5: 148-8361 Elbow (from balancing line)

For all machines:
Check for possible internal plug-orifice loosening. (Machine may have been reported like difficulty to lower boom, and noisy operation)
After taking all required safety precautions:
Remove 225-4820 Plug Assembly (3).
Inspect 114-8229 or 8J-6815 Plug-Orifice (4) that is located behind the plug assembly for loosening.
Replace the plug-orifice with a 8J-6815 Plug-Orifice, without Loctite, and tighten to a torque of 13 +/-2 Nm.
Replace 3J-7354 Seal from 225-4820 Plug Assembly (3) with a new one in order to avoid a leak. Tighten the plug assembly to a torque of 23 +/-2 Nm.
Disconnect the balancing line and elbow (5) from BLCV. Inspect 114-8229 or 8J-6815 Plug-Orifice (4) that is located behind the elbow for loosening. Replace the plug-orifice with a 8J-6815 Plug-Orifice, without Loctite, and tighten to a torque of 13 +/-2 Nm. Re-install fitting and balancing line. Replace seal if required. Perform this procedure for the second BLCV.

Start the engine.
Select low engine speed dial.
Slowly move the joystick to raise the boom 1 meter off the ground and then lower it back down again. Repeat this operation 10 times to purge the air.

If you experience a problem with the BLCV that has not been solved by applying this procedure, contact your dealerships Technical Communicator (TC). Have the TC contact the Dealer Solution Network (DSN) to get to the Gosselies Product Support Engineer. Please provide the machine serial number, machine hours, and the failure type. There may be a demand for valve analysis in Gosselies.