PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING, IF NEEDED, THE BOOM AND BUCKET CYLINDERS ON CERTAIN 330D, 330D MH, 345C AND 345D EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING, IF NEEDED, THE BOOM AND BUCKET CYLINDERS ON CERTAIN 330D, 330D MH, 345C AND 345D EXCAVATORS [REBE4143]

HYDRAULIC SYSTEM

CYLINDER GP

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING, IF NEEDED, THE BOOM AND BUCKET CYLINDERS ON CERTAIN 330D, 330D MH, 345C AND 345D EXCAVATORS

REBE4143-00

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21Jul2008

U-384

A-312

O-350

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING, IF NEEDED, THE BOOM AND BUCKET CYLINDERS ON CERTAIN 330D, 330D MH, 345C AND 345D EXCAVATORS
5059 5457 5456		PI10702

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10702" 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 "PI10702" 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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An oversized locknut may have been assembled in some cylinders on certain 330D, 330D MH, 345C, and 345D Excavators. The oversized locknut can introduce contamination in the hydraulic system resulting in unwanted or unexpected movement that may cause injury or death.

AFFECTED PRODUCT

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Model	Identification Number
330D	THJ00332-00334
330D MH FCR	LEM00212, 219-225
345C	PJW02435-02442 TDG00412
345D L	EEH00222-00233, 235-258, 262-265, 267-274, 277-279, 282, 285-286, 288-289, 293 RAJ00234-00245, 248-252 YEE00242-00249

PARTS NEEDED

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Qty	Part Number	Description
2	2254523	Boom Cylinder Gp (If Required)
1	2254529	Bucket Cylinder Gp (If Required)
1	2707888	Boom Cylinder Gp (If Required)
1	3100147	Valve Gp -Boom Lowering Regeneration (If Required)

ACTION REQUIRED

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The affected machines will need to have the listed cylinders inspected for the non-conforming nut. Cylinders that are found to have the non-conforming nut will need to be replaced with a new cylinder and the hydraulic system flushed.

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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
Note: The 1 hour provided in the initial service allowance is for the visual and bore scope inspection of one cylinder. Note: An additional 4 hours labor and applicable parts will be allowed for each cylinder requiring replacement. Note: An additional 1 hour will be allowed to flush each of the boom or bucket hydraulic circuits if a non-conforming cylinder is discovered. Note: An additional 5 hours labor and applicable parts will be allowed for each regeneration valve requiring replacement.

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PARTS DISPOSITION

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Cylinders with non-conforming nuts should be returned to AVSpare. Please return the cylinders to the address listed below. For machines located outside of NACD, please handle the parts in accordance with the warranty guidelines.

For NACD

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AVSpare Inc.

Attn: Supplier Recovery

Service Claims Room

8201 N. University

Peoria, IL 61615

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 INSPECTING AND REPLACING, IF NEEDED, THE BOOM AND BUCKET CYLINDERS

MODELS INVOLVED - 330D, 330D MH, 345C, 345D Excavators

Dear AVSpare Product Owner:

The boom and bucket cylinders need to be inspected and possibly replaced on the products listed below. The existing cylinders can introduce contamination to the hydraulic system. This contamination can cause unexpected movement that 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 21Jul2008 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 21Jul2008 Service Letter

Rework Procedure

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Date Code Inspection Procedure:
1. Inspect the boom and bucket (if applicable) cylinders for a date code. On the boom cylinders, the date code should be on the bottom of the barrel near the head end of the cylinder. On the bucket cylinder, it should be on the right hand side of the barrel at the head end. The code may be under the oil tube attached to the cylinder.

Image1.1.1

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2. The date code needs to be BEFORE 4/21/08 to be a good cylinder. If the date code is before 4/21/08, the cylinder is good and no further action is required.
Any date code after 4/21/08 is suspect and needs to be visual inspected internally with a bore scope. The date code may be in a different location or may be thickly painted and unreadable.

Here is an example of a BAD date code on the cylinder.

Image1.2.1

3. If the date code on the cylinder is after 4/21/08 or if the date code is unreadable or missing, the cylinder will need to be checked internally with a bore scope.
4. Record the results of the visual inspection. Record the machine serial number, cylinder inspected and the date code.

Bore Scope Inspection Procedure:

You will need the following tooling (or equivalent) to perform the testing:
186-0170 Flexible Bore Scope
1U-5266 Light Source for Bore Scope

Image1.4.1

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Boom Cylinder Inspection:

Prior to starting any work on the machine, please review, understand and adhere to all safety and environmental warnings in the appropriate disassembly and assembly manual.

1. Extend the boom cylinder rods ? of their length, rest the stick and bucket on the ground and turn the machine off. Release the pressure from the hydraulic system.

2. Remove the fitting from the bottom of the boom cylinders. On the 330D MH, the drift reduction valve will need to be removed from the cylinder. Remove the two bolts on the brackets holding the boom cylinder tubes.

Image1.5.1

3. Move the flange aside and use suction to remove the hydraulic oil from the cylinder.
4. Insert the flexible bore scope into the port on the cylinder until the locknut on the piston can be seen.

Image1.6.1

5. Visually determine if the nut is conforming or non-conforming. The conforming nut has rounded corners. Non-conforming nuts have sharp corners and may have signs of damage.

6. Remove the bore scope from the cylinder. Repeat the procedure for the other boom cylinder.
7. Record the results of the inspection. Record the machine serial number, cylinder inspected and results of the inspection.
8. If the non-conforming nut is found, the cylinder will need to be replaced with a new complete cylinder. Do not attempt to repair the cylinder.

Bucket Cylinder Inspection:

1. Curl the bucket and the stick under the boom to allow easy access to the bucket cylinder. Extend the bucket cylinder rod ? out of the cylinder. Rest the bucket on the ground and turn the machine off. Release the pressure from the hydraulic system.
2. Remove the four bolts and the block from the bucket cylinder.

Image1.9.1

3. Use suction to remove the hydraulic oil from the cylinder.
4. Insert the flexible bore scope into the port on the cylinder until the locknut on the piston can be seen.
5. Visually determine if the nut is conforming or non-conforming. The conforming nut has rounded corners. Non-conforming nuts have sharp corners and may have signs of damage.
6. Remove the bore scope from the cylinder. Reinstall the block and the bolts on the cylinder.
7. Record the results of the inspection. Record the machine serial number, cylinder inspected and results of the inspection.
8. If the non-conforming nut is found, the cylinder will need to be replaced with a new complete cylinder. Do not attempt to repair the cylinder.

Bucket Cylinder Replacement Procedure:

1. Remove the bucket cylinder. Refer to 345C Disassembly and Assembly instructions for bucket cylinder removal (medial number RENR8612-04).
2. Attach bucket lines together.

Image1.11.1

3. From Tool A, assemble the couplings (153-0834 and 153-0865) to 122cm (48 inches) of 161-1819 (XT-6 ES 1? ID hose).

Image1.12.1

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4. From Tool A, install 6V-9840 on the swing motor return line (attach line to same location as when performing a single pump flow test).

Image1.13.1

5. Remove bucket line and block the line. Attach hose assembly from Tool A to the bucket line and the tee on the swing motor return line.

Image1.14.1

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6. Flush the line using the bucket circuit. Cycle the valve for a total of 5 minutes by performing 1 minute intervals of holding the control level in the bucket close position and then pausing between intervals. During the pause, quickly actuate the bucket valve from neutral to close.
7. Remove tube assembly from the used bucket cylinder. Use appropriate hose cleaning tool with projectile to clean the tube assembly of the removed bucket cylinder.
8. Remove Tool A components and re-attach bucket cylinder hose to bucket cylinder tube assembly on the boom.
9. Install cleaned tube assembly to new bucket cylinder.
10. Install new bucket cylinder on the machine. Refer to 345C Disassembly and Assembly instructions for bucket cylinder installation (medial number RENR8612-04).

Boom Cylinder Replacement Procedure:

1. Remove boom cylinder. Refer to 345C Disassembly and Assembly instructions for boom cylinder removal (medial number RENR8612-04).
2. Remove the bracket over boom regeneration valve. Two bolts hold the bracket in place.

Image1.16.1

3. Remove the boom regeneration spool cover. After removing the bolts, lift up the cover enough to insert your fingers under the cover and shims. Once your fingers are under the shims, grab the spring and remove the cover, shims, and spring out of the block together.

Image1.17.1

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4.Insert a 4 inch M-8 bolt (P/N - 8T-4177) into the top of the boom regeneration spool.

Image1.18.1

5. Remove the boom regeneration spool. The spool should provide some resistance. If the spool cannot be removed, the boom regeneration valve needs to be replaced.
6. Once the spool is removed, inspect the spool for damage. If damage is found on the spool, the entire valve needs to be replaced.

* If the boom regeneration valve is replaced, use appropriate hose cleaning tool with projectile to clean the hose assemblies of the boom regeneration valve for installation to the new boom regeneration valve.

7. If the spool is not damaged, insert a clean magnet into the bore of the regeneration valve. Remove any foreign material that maybe present.
8. Install the spool, spring, shims, cover, and guard on the boom regeneration valve.
9. Use a cable tie to bind the two boom hydraulic hoses together. Use another cable tie to bind the two hoses to one of the bolts on the ring gear. This will prevent the hoses from moving during the flushing process.
10. Place a drum under the hose to catch the oil that will be flushed from the system.

Image1.19.1

11. Make sure that there is appropriate amount of hydraulic oil in the hydraulic tank and then start the machine. Let the machine idle for 40 ? 60 seconds to flush any contaminants from the boom regeneration valve. DO NOT actuate any of hydraulic levers during this process.
12. Remove tube assembly from the used boom cylinder. Use appropriate hose cleaning tool with projectile to clean the tube assembly of the removed boom cylinder.
13. Install cleaned tube assembly to new boom cylinder.
14. Install new boom cylinder on the machine. Refer to 345C Disassembly and Assembly instructions for bucket cylinder installation (medial number RENR8612-04).
15. Re-attach the boom hose assemblies to the new boom cylinder.