PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE COUNTERWEIGHT REMOVAL CHAIN ON CERTAIN 345B, 345B SERIES II, AND 345C EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE COUNTERWEIGHT REMOVAL CHAIN ON CERTAIN 345B, 345B SERIES II, AND 345C EXCAVATORS

Usage:

REBE4360-03

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19Sep2008

(Revised 13Feb2009)

U-485

A-397

O-443

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*Safety*	PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE COUNTERWEIGHT REMOVAL CHAIN ON CERTAIN 345B, 345B SERIES II, AND 345C EXCAVATORS
7056 6404		PI10716

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10716" 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 "PI10716" 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 19Sep2008 (Revised 22Dec2008) Service Letter. Changes have been made to the Affected Product and the Rework Procedure.

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PROBLEM

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The existing counterweight removal chain may fail on certain 345B, 345B Series II, and 345C Excavators. This could potentially cause the counterweight to drop unexpectedly when being lowered or raised by means of the counterweight removal system. This unexpected drop may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
345B	4SS00214-00288, 290-316, 318-334, 337-340, 345-351, 353-356, 358, 362-363, 366-369, 371-374, 376, 378-380, 382-388, 393-398, 401, 407, 409-410, 416-417, 419-425, 429-435, 437, 439-440, 451-453, 458-459, 461, 465-467, 469-471, 476, 481-482, 486, 496-498, 501, 506-508, 510-511, 515-517, 520-521, 526, 529, 531, 534, 542, 551, 556, 564-565, 579, 582, 586, 588, 590-591, 594-597, 600, 604-605, 610-611, 616, 618-619, 625-627, 630-633, 640, 646, 648-650, 652, 654, 657, 672, 674, 677, 682, 684, 686, 691, 696, 705, 707-711, 713-715, 717, 722, 726-727, 737, 739, 746, 749, 751, 755-760, 762, 764, 770, 773-774, 778, 780, 783-784, 788, 791, 793, 797, 799, 803, 805, 809, 812, 814, 817, 822-823, 828, 830-831, 836-839, 841-845, 850, 854-855, 858, 863, 865-868, 873, 876-878, 881, 892-893, 896, 901, 906-907, 910, 914, 918, 920, 923-924, 927-928, 937, 944, 953, 955, 961, 964-965, 972, 974-975, 977-978, 980-981, 988-989, 994, 1014, 1017, 1019, 1022, 1025-1027, 1031-1034, 1038, 1048-1049, 1051, 1058, 1062, 1066, 1068, 1070, 1075, 1077-1079, 1082, 1085, 1087-1088, 1095, 1098, 1110, 1117, 1121, 1124-1125, 1129, 1131, 1135-1136, 1143, 1145, 1149, 1152, 1154-1155, 1157, 1159, 1162, 1165, 1168, 1170-1174, 1177, 1179-1181, 1183, 1186-1187, 1189-1190, 1192-1193, 1197, 1202, 1222, 1225-1226, 1228-1229, 1232, 1235, 1240, 1242, 1245-1247, 1250, 1254, 1256, 1261-1262, 1264-1265, 1275, 1282, 1286, 1290, 1302, 1314, 1318, 1321, 1323, 1328, 1334, 1336-1338, 1342-1348, 1350, 1352, 1355, 1359, 1363-1364, 1370, 1383, 1385-1387, 1391-1401, 1404-1405, 1407-1409, 1417-1423, 1428, 1430, 1435-1436, 1449-1451, 1459, 1461, 1469, 1471, 1473, 1475-1476, 1479, 1482-1483, 1490-1491, 1500, 1508-1509, 1511-1520, 1525, 1528-1529, 1545-1546, 1569-1570, 1577, 1583, 1595, 1601, 1610, 1613, 1620-1621, 1629, 1632, 1639-1640 9GS00166-00170, 174-176, 178-180, 182-183, 185, 187, 195-196, 198-201, 203, 205, 209-211, 216-217, 219, 221, 223-225, 227-228, 234-235, 250, 253, 256-257, 262-265, 275, 278-281, 285
345B II	DCW00299, 302-303, 308-311, 315-316, 319, 322, 325-335, 337
345B II LC-FIX	AGS00212-00214, 217, 224-226, 228, 236-238, 240, 242-243, 270, 288, 293, 295, 298-299, 309, 321, 327, 331, 334, 346, 348-349, 351-352, 357, 364-365, 369, 373, 375-378, 380, 384, 388, 392, 412-413, 423, 431-432, 439, 441, 443, 445, 449-450, 454, 461, 465, 472, 476, 483, 485, 495, 497-498, 500, 502, 515-519, 526, 530, 532, 534, 542, 544-546, 548-552, 554-555, 557-558, 564, 566, 568-570, 572, 574-577, 579-582, 584, 589, 591, 593-595, 601, 608, 611, 613, 615-616, 618, 622, 628, 701, 707, 710, 726, 738, 747-749, 751-752, 754, 759, 767, 770-771, 777, 791, 797, 801, 803, 805-806, 815-817, 819-824, 827, 832, 843, 845-846, 849-851, 856-857, 859, 863, 868, 871, 873-874, 878, 882-883, 885, 899, 904, 912, 915, 922, 925-926, 935, 941, 946, 959, 962-963, 972-974, 982, 984, 996-997, 1006-1007, 1009, 1014, 1025-1033, 1043, 1045-1056, 1059-1060, 1062-1065, 1067-1074, 1080-1081, 1084-1085, 1089-1097, 1100-1134, 1137-1143, 1146-1147, 1150-1152, 1166-1168, 1189, 1192, 1207, 1213, 1215-1216, 1227-1228, 1230, 1243-1246, 1251, 1255, 1257-1258, 1260, 1264, 1280, 1288-1289, 1297, 1299-1301, 1303, 1316, 1325, 1331, 1336, 1348, 1352, 1355-1361, 1368, 1371-1373, 1375, 1383-1384, 1388-1389, 1400, 1406-1407, 1409-1411, 1416-1417, 1420-1421, 1426, 1429-1431, 1434, 1450, 1459, 1462, 1464-1465, 1467, 1469, 1482-1483, 1485, 1489-1490, 1492, 1494-1495, 1500-1503, 1506, 1511-1512, 1516-1517, 1522, 1524, 1527, 1531, 1533-1534, 1536, 1538-1539, 1541, 1551-1555, 1561, 1572-1573, 1575, 1580, 1582-1583, 1585, 1587, 1591-1592, 1599, 1602, 1604, 1606, 1609, 1611, 1614, 1616, 1618, 1620, 1623-1625, 1627, 1629, 1638, 1640-1641, 1644-1646, 1649, 1654-1655, 1659, 1665-1666, 1674, 1687, 1689, 1704, 1729, 1732-1733, 1755, 1764, 1770, 1772-1773, 1776, 1783-1784, 1819, 1823, 1825, 1827-1828, 1834-1835, 1845, 1849, 1852-1856, 1858-1859, 1861, 1865, 1868, 1871, 1875, 1879-1881, 1884, 1893-1894, 1902, 1909, 1912-1913, 1917-1918, 1921, 1927-1930, 1937, 1940-1941, 1944-1945, 1948, 1952-1953, 1955, 1959, 1962-1963, 1980, 1984-1985, 1991, 2008, 2010, 2018, 2021, 2027, 2055, 2067-2068, 2084, 2098-2101, 2107, 2142-2144, 2156, 2160, 2174, 2179, 2184-2185, 2187-2188, 2190, 2193-2194, 2196, 2200-2203, 2206-2207, 2209, 2211-2212, 2214, 2217, 2223-2224, 2226, 2232, 2234, 2238, 2242-2243, 2248, 2252-2253, 2256, 2270, 2279, 2281, 2285, 2287, 2289-2292, 2300, 2304, 2306, 2309-2310, 2313, 2319, 2323-2324, 2332, 2339, 2341, 2343, 2345, 2347, 2349, 2352-2353, 2355-2356, 2358-2359, 2361, 2363, 2367, 2383, 2387, 2393-2394, 2396, 2398, 2405, 2413, 2416, 2423, 2426, 2443, 2448, 2451, 2456-2458, 2460, 2465-2467, 2469, 2474, 2481, 2486-2488, 2490, 2492, 2495, 2498, 2501, 2504, 2507-2508, 2519, 2523, 2527-2528, 2538, 2544-2545, 2550-2553, 2555, 2557-2558, 2563, 2572, 2576, 2581-2582, 2586, 2590, 2596-2597, 2601, 2603-2604, 2608, 2612, 2614-2615, 2618-2620, 2622-2623, 2625-2626, 2631, 2633-2636, 2641, 2643, 2646, 2652, 2655-2657, 2662-2663, 2665, 2667, 2671-2672, 2681-2682, 2684-2685, 2709, 2712, 2729-2730, 2736, 2743, 2748-2749, 2756-2757, 2760, 2762, 2769, 2772-2774, 2777-2778, 2780-2782, 2784, 2786, 2788-2790, 2793, 2795, 2797-2799, 2804, 2806-2808
345B L II	ALB00187-00188, 195-196, 198-199, 301-302, 304, 310-311, 315, 317-318, 320, 322-323, 325-333, 338, 340, 345, 349-351, 354, 357, 361-362, 366, 368, 373, 376-379, 381 CCC00447, 545

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*****Group 2*****
345C	ESD00170-00174, 176-177, 181, 183-184, 189-196, 199, 205-207, 209, 211, 214-218, 220-221, 223, 228-229, 234-236, 241, 244-245 PJW00368, 370-371, 375, 381, 386, 390, 394, 402, 418-419, 421-422, 427, 429, 433-436, 438, 448, 459-460, 470, 473, 479-480, 482, 485, 494, 497-499, 505-506, 521, 526, 529, 534, 541, 547, 556, 559, 561-562, 570, 584, 588, 591, 601, 608, 616, 618-619, 621-622, 625-626, 634-635, 643, 647, 650, 658, 663, 673-675, 682, 688, 697, 699, 702, 706-707, 713-714, 716-719, 724, 728-729, 731-738, 743, 745, 753-754, 761, 763-765, 769, 774-775, 778, 785-789, 794-797, 799, 804-806, 808, 810-812, 816, 818, 820, 822, 828, 830, 833, 844, 847, 851, 864-865, 874, 879, 883, 885, 887, 894-895, 898, 902-906, 912, 914, 916, 919-920, 922, 925, 927, 930-932, 935-939, 950, 953, 957, 961, 976-979, 981, 986, 1002-1003, 1017, 1019-1022, 1024-1025, 1029, 1035-1036, 1043, 1065, 1067, 1074, 1077, 1107-1108, 1115-1117, 1124, 1146, 1164, 1166-1167, 1177, 1180, 1191-1192, 1194, 1206, 1216-1217, 1219, 1227, 1229, 1232-1234, 1245, 1247, 1252, 1256, 1262-1263, 1265, 1269, 1277-1278, 1281-1283, 1287, 1294-1296, 1300, 1305-1307, 1313, 1318-1319, 1322, 1324-1326, 1328, 1337, 1344-1345, 1354, 1357, 1360-1361, 1373-1379, 1385-1386, 1395-1396, 1398, 1402-1403, 1405, 1413, 1415-1416, 1420-1421, 1427, 1429, 1432, 1437, 1441, 1445, 1450, 1457, 1465, 1467, 1482, 1490, 1506, 1515, 1524-1525, 1530, 1534, 1536, 1540, 1547, 1549, 1564, 1578, 1598, 1606, 1611, 1617, 1625, 1629, 1631, 1635, 1639, 1641, 1645, 1651, 1667, 1675, 1687, 1695, 1717, 1749, 1756, 1759-1760, 1762-1765, 1767-1769, 1779-1782, 1786, 1790, 1798-1800, 1805-1806, 1810-1811, 1813, 1819-1820, 1833, 1839, 1844, 1861-1862, 1882, 1902, 1910, 1913, 1915-1916, 1918, 1920-1925, 1927-1929, 1931-1932, 1934, 1936-1937, 1941, 1944, 1948, 1952-1954, 1986, 1996, 2018, 2021, 2024, 2033, 2038-2039, 2045-2050, 2052-2054, 2057-2058, 2062-2063, 2065, 2091-2092, 2100, 2102-2103, 2106-2107, 2110-2111, 2116-2117, 2125, 2130, 2133-2134, 2136, 2140-2141, 2143-2145, 2161-2162, 2166, 2168-2169, 2178, 2187, 2204, 2211-2213, 2215, 2225-2227, 2230-2233, 2237, 2242, 2253, 2255, 2262, 2265, 2267, 2269-2270, 2272, 2274, 2285, 2288, 2292-2293, 2297, 2302, 2312, 2314-2316, 2326-2329, 2335-2336, 2340, 2370-2371, 2375-2376, 2379, 2381, 2392-2393, 2400, 2404, 2406, 2408, 2411-2414, 2416, 2422, 2427, 2432, 2435 TDG00250-00251, 267, 277, 281-286, 288, 292, 299-300, 302-303, 319, 331-332, 334-335, 337, 344-345, 347, 353, 365, 370-373, 378-379, 384, 392-393, 402
345C L	TAJ00266

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	7Y1537	NUT-SELF LOCKING
1	0860507	PIN
2	0930349	WASHER
1	0964879	NUT-HEX
1	1276741	PIN
2	1276742	PIN
1	3312019	CHAIN AS-LIFT
Due to limited availability, dealers should limit there orders to less than 5 per week and no more than 10 per month, unless authorized by Aurora Product Support.
*****Group 2*****
2	7Y1537	NUT-SELF LOCKING
1	0860507	PIN
2	0930349	WASHER
1	0964879	NUT-HEX
1	1276741	PIN
2	1276742	PIN
1	3312019	CHAIN AS-LIFT
Due to limited availability, dealers should limit there orders to less than 5 per week and no more than 10 per month, unless authorized by Aurora Product Support.

ACTION REQUIRED

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Remove the machine counterweight and replace the existing counterweight removal chain with a new counterweight removal chain. Adjust the relief valve for the counterweight removal cylinder to a new pressure setting. Refer to the attached Rework Procedure.

If the counterweight chain has already been replaced, the counterweight valve pressure adjustment will need to be performed. A second trip will be required to adjust the pressure setting on machines that have already installed new counterweight chains.

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OWNER NOTIFICATION

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

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 5.5-hour job for Group 1
NOTE: A $600 misc expense for crane charges will be allowed to remove the counterweight and install the new chain.

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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 5.5-hour job for Group 2
NOTE: A $600 misc expense for crane charges will be allowed to remove the counterweight and install the new chain.

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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 NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE COUNTERWEIGHT REMOVAL CHAIN

MODELS INVOLVED - 345B, 345B SERIES II, AND 345C EXCAVATORS

Dear Caterpillar Product Owner:

The counterweight removal chain assembly needs to be replaced on the products listed below. This chain assembly may fail, and could cause the counterweight to drop unexpectedly when being lowered or raised by means of the counterweight removal system. This unexpected drop may result in personal injury or death.

However, limited quantities of this replacement chain assembly will be available from Caterpillar each month. Because of this limited supply, distribution of the chain assemblies will be made accordingly. Until the new chain assembly is installed, continue to use appropriate lifting equipment to manually remove or install the counterweight. Follow the procedures in the Operation and Maintenance Manual for "Counterweight Removal and Installation for Standard Machines".

Please contact your local Caterpillar dealer to confirm the previous communication that was released on June 25, 2008, to cease operation of the counterweight removal system, has been completed on your machine. Your local dealer will inform you when parts are available to update your machine. At that time, arrangements can be made with your Caterpillar dealer to install this new chain assembly, which will allow you to use the counterweight removal system. You will not be charged for the service performed.

Please refer the dealer to their Service Letter dated 19Sep2008 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.

Caterpillar Inc.

Identification #(s)

Attached to 19Sep2008 Service Letter

Rework Procedure

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Group Number 1

Group 1
Counterweight Removal

Prior to starting any work on the machine, please review, understand and adhere to all safety and environmental warnings in the applicable Operation and Maintenance Manual.

For counterweight removal instructions for the 345B refer to SEBU7029, Operation and Maintenance Manual, "Counterweight Removal and Installation for Standard Machines" for specific weight information.

For counterweight removal instructions for the 345B Series II refer to SEBU7289, Operation and Maintenance Manual, "Counterweight Removal and Installation for Standard Machines" for specific weight information.

1. Position the machine on a surface that is hard and level. Lower the work tool to the ground.
2. Move the hydraulic lockout control to the LOCKED position. Remove the five bolts (1) and washers (2) from cover (3). Remove cover (3).
3. Remove the six bolts (1) and washers (2) from cover (4). Remove cover and (4).

Image1.1.1

4. Fasten a properly rated cable with shackles to the brackets. Use an appropriate lifting device in order to put tension on the cable. If the tension in the cable is too much or too little, removing or installing the bolts will be difficult.

Image1.2.1

5. Remove six counterweight mounting bolts and six washers.

Image1.3.1

6. Remove two bolts, two washers and a plate, which is located below the counterweight.
7. Lift the counterweight enough so that there is no load on the retaining bolts.
8. Lower the counterweight onto supports on the ground.
9. Remove cotter pin (6). Loosen nut (7). Remove pin (8) in order to disconnect chain bracket (9) from counterweight (5).

Image1.4.1

10. Separate the counterweight from the machine. Lower the counterweight onto suitable supports

Image1.5.1

Counterweight Removal Chain Disassembly

For additional information on counterweight chain removal instructions for the 345B and 345B Series II refer to SENR1934, Disassembly and Assembly, "Counterweight Cylinder ? Remove".

1. Attach a lifting strap and a hoist to the middle of chain assembly (1). Lift the chain assembly until the hoist, as shown, supports the chain assembly.

2. Remove the nut, the washer, and bolt (2).

Image1.7.1

3. Remove chain assembly (1). The weight of the chain assembly is 30 kg (66 lb).
4. Repeat Steps 1 through 3 in order to remove the other chain assembly.

Image1.8.1

Counterweight Removal Chain Installation

For additional information on counterweight chain installation instructions for the 345B and 345B Series II refer to SENR1934, Disassembly and Assembly, "Counterweight Cylinder ? Remove".

1. Attach a lifting strap and a hoist to the middle of the new chain assembly (1). Position the chain assembly on the machine, as shown.

2. Install bolt (2), the washer, and the locknut. Tighten the locknut to a torque of 98 +/- 10 Nm (72.3 +/- 7.4 lb ft). Lower the chain assembly on the sprocket. Remove the lifting strap and the hoist from the chain assembly.

Image1.10.1

3. Repeat Steps 1 and 2 in order to install the other chain assembly.

Image1.11.1

NOTE: Ensure the counterweight chain sprocket on the counterweight removal cylinder moves freely and it is properly lubricated.

Counterweight Installation

Use standard procedure for installing machine counterweight.

For additional information on counterweight installation instructions for the 345B refer to SEBU7029, Operation and Maintenance Manual, "Counterweight Removal and Installation for Machines That Are Equipped with a System for the Removal of the Counterweight".

For additional information on counterweight installation instructions for the 345B Series II refer to SEBU7289, Operation and Maintenance Manual, "Counterweight Removal and Installation for Machines That Are Equipped with a System for the Removal of the Counterweight".

Image1.13.1

Counterweight control valve relief valve pressure setting

NOTE: This procedure is to be performed with the counterweight bolted to the machine.

1. Increase the hydraulic oil temperature to 55?+/- 5?C (131?+/-9?F).
2. Position the machine on a surface that is hard and level.
3. Position the upper structure parallel to the tracks. Lower the work tool to the ground.
4. Open the right rear access door in order to gain access to the counterweight control valve.

Image1.14.1

5. Connect a 28000kPa (4000 psi) pressure gauge to pressure tap for upper pump delivery pressure.

Image1.15.1

6. Start the engine and adjust the engine speed to dial speed 1.
7. Move the hydraulic lockout control to the LOCKED position. Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls.
8. Return to the access door on the right side of the machine to operate counterweight removal system.

Image1.16.1

9. Move switch upward to the ON position.
10. Move both stop valves to the OPEN position.
11. Move control lever downward to fully retract counterweight removal cylinder.
12. Loosen lock nut on the Counterweight Removal Control Valve.

13. Hold control lever downward for five seconds. After five seconds, continue to hold lever down and adjust the relief valve pressure.
14. Turn adjustment screw until the pressure gauge reading is 17200+700/-0 kPa (2500+100/-0 psi).
15. Tighten locknut to a torque of 29+/-2 Nm (22+/-1 lb ft).

Note: Turning adjustment screw clockwise increases the pressure and turning adjustment screw counterclockwise decreases the pressure.

Note: Always make final pressure adjustments on pressure rise.

16. Move both stop valves to the CLOSED position.
17. Move switch upward to the OFF position.
18. Stop engine and remove pressure gauge.

Group Number 2

Group 2
Counterweight Removal

Prior to starting any work on the machine, please review, understand and adhere to all safety and environmental warnings in the applicable Operation and Maintenance Manual.

For the 345C refer to SEBU7861, Operation and Maintenance Manual, "Counterweight Removal and Installation for Standard Machines" for specific weight information.

1. Position the machine on a surface that is hard and level. Lower the work tool to the ground.
2. Move the hydraulic lockout control to the LOCKED position. Remove the five bolts from cover (1).

Image2.1.1

3. Raise, or remove, the counterweight cover plate as shown. Use bar (2) in order to support the cover while the cover is in the OPEN position.

Image2.2.1

4. Fasten a proper rated cable with shackles. Use an appropriate lifting device in order to put tension on the cable.

Image2.3.1

5. Lift the counterweight enough so that there is no load on the retaining bolts. Removing the bolts is difficult if the cable is too tight or too loose.
6. Remove the six counterweight mounting bolts and six washers.

Image2.4.1

7. Lower the counterweight onto supports on the ground.
8. Remove cotter pin (4). Loosen nut (5). Remove pin (6) in order to disconnect chain bracket (7) from counterweight (3).

Image2.5.1

9. Separate the counterweight from the machine. Lower the counterweight onto suitable supports.

Counterweight Removal Chain Disassembly

For additional information on counterweight chain removal instructions for the 345C refer to RENR8612, Disassembly and Assembly, "Counterweight Cylinder ? Remove".

1. Attach a suitable lifting device to chain assembly (1). The weight of chain assembly (1) is approximately 61 kg (135 lb). Lift chain assembly (1) until chain assembly (1) is supported by the lifting device.

Image2.7.1

2. Remove bolt (2). Repeat for the opposite side. Remove chain assembly (1).

Image2.8.1

Counterweight Removal Chain Installation

For additional information on counterweight chain installation instructions for the 345C refer to RENR8612, Disassembly and Assembly, "Counterweight Cylinder ? Remove".

1. Attach a suitable lifting device to the new chain assembly (1). The weight of chain assembly (1) is approximately 61 kg (135 lb). Position chain assembly (1).