Inspection Procedure for Boom Cylinder Assembly Cracks on Certain 330B, 330C, 345B, 345C, and 345D Excavators {5456, 7562} Caterpillar

Excavator

330B (S/N: 9HN1-595; 2RR1-646; 3YR1-1893; 5LR1-1129; 6DR1-5197; 8SR1-672; 8TR1-957; 1JS1-551; 4RS1-642; 5LS1-325; 4YW1-275; 3ZZ1-203; 5EZ1-302)

330C (S/N: CYA1-1250; HAA1-583; MCA1-3180; JAB1-847; JCD1-375; KDD1-1704; GAG1-484; RBH1-272; JNK1-354; BTM1-234; CAP1-2294; GKX1-580; DKY1-23434; CGZ1-995)

345B (S/N: BFG1-404; 7KS1-1125; 2SW1-219)

345B Series II (S/N: CCC1-1371; FEE1-302; CDJ1-201; DET1-115)

345C (S/N: FPC1-146; SPC1-283; GPH1-537; GCL1-279; SCN1-206; ELS1-179; LYS1-190)

345D (S/N: RGD1-149; RGG1-269; KFH1-211; LKY1-256)

Mobile Hydraulic Power Unit

330C MHPU (S/N: MSD1-298; MSL1-1911)

345C MHPU (S/N: NRF1-104; B6N1-171)

345D MHPU (S/N: P5D1-158)

Introduction

This Special Instruction provides the procedure to inspect the boom cylinder assembly for cracks on certain 330B, 330C, 345B, 345C, and 345D Excavators. Follow all of the safety instructions before proceeding.

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Be sure all personnel are clear of equipment while equipment is being lowered. Failure to stay clear may result in personal injury.

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Personal injury can result from working with cleaning solvent. Because of the volatile nature of many cleaning solvents, extreme caution must be exercised when using them. If unsure about a particular cleaning fluid, refer to the manufacturer's instructions and directions. Always wear protective clothing and eye protection when working with cleaning solvents.

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Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

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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 work tools 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.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Required Parts

Reference

Reference: 330B Disassembly and Assembly, SENR8973, "Boom Cylinder"

Reference: 330C Disassembly and Assembly, RENR5438, "Boom Cylinder - Remove"

Reference: 330C Disassembly and Assembly, RENR5438, "Boom Cylinder - Install"

Reference: 345B Disassembly and Assembly, SENR1934, "Boom Cylinder - Remove"

Reference: 345B Disassembly and Assembly, SENR1934, "Boom Cylinder - Install"

Reference: 345C Disassembly and Assembly, RENR8612, "Boom Cylinder - Remove and Install"

Reference: 345D Disassembly and Assembly, RENR9574, "Boom Cylinder - Remove and Install"

Inspection Procedure

Illustration 1	g06033762
Boom cylinder (1) Boom cylinder group (2) Clamp (3) Boom lines

Illustration 2	g06020348
Boom cylinder inspection area (1) Boom cylinder group (2) Clamp (3) Boom lines (A) 50.8 mm (2.0 inch) (B) Crack inspection area

1. Remove boom cylinder (1). Refer to Disassembly and Assembly manual.

2. Remove boom cylinder clamp (2) and boom lines (3) to gain access to crack inspection area (B), refer to Illustration 1 and Illustration 2.

3. Inspect crack inspection area (B) using liquid penetrant examination. Refer to Section "Liquid Penetrant Examination".

4. If no cracks are found, clean solvent off boom cylinder (1) with a cloth.

   Note: Ensure all of the area exposed to the dye penetrant process is cleaned.

5. Sand cylinder and repaint the boom cylinder.

6. Reinstall boom cylinder (1). Refer to Disassembly and Assembly manual.

7. If a crack is found, replace the boom cylinder assembly.

Note: Use same procedure to inspect both boom cylinders.

Liquid Penetrant Examination

Materials Required

Refer to Table 1 for part numbers.

• Cleaner: Removes dirt before dye application and dissolves the penetrant making possible to wipe the surface clean.

• Penetrant: This solution is highly visible, and will seep into openings at the surface of a part with capillary action.

• Developer: Provides a blotting action, bringing the penetrant out of the discontinuities and providing a contrasting background to increase the visibility of the penetrant indications.

• Wire Brush: Removes dirt and paint.

• Cloth or Wipes: Use with cleaner and for other miscellaneous uses.

Procedure

Illustration 3	g03791241

1. Remove paint within the entire circumference of the inspection area (B) on boom cylinder (1). Wipe the area to inspect with a solvent dampened cloth to remove remaining dirt and allow the area to dry.
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   Illustration 4	g03791250

2. Apply penetrant by spraying to the entire area to be examined. Allow 10 to 15 minutes for penetrant to soak. After the penetrant has been allowed to soak, remove the excess penetrant with clean, dry wipe.
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   Illustration 5	g03791397

3. The last traces of penetrant should be removed with the cleaner solvent dampened cloth or wipe. Allow the area to dry thoroughly.
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   Illustration 6	g03791251

4. Before using developer make sure that, it is mixed thoroughly by shaking can. Holding can approximately 8-12 inches away from part, apply an even, thin layer of developer over the area being inspected. A few thin layers are a better application method than one thick layer.
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   Illustration 7	g06029540

5. Allow the developer to dry completely for 10–15 minutes before inspecting for cracks. Defects will show as red lines (C) in white developer background. Clean the area of application of the developer with solvent cleaner.