PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND RETIGHTENING THE COUNTERWEIGHT REMOVAL CYLINDER LOWER BRACKET BOLTS ON CERTAIN 374D AND 390D EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND RETIGHTENING THE COUNTERWEIGHT REMOVAL CYLINDER LOWER BRACKET BOLTS ON CERTAIN 374D AND 390D EXCAVATORS

Usage:

TEBE0349-01

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09Oct2013

(Revised 21Apr2014)

U-494

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND RETIGHTENING THE COUNTERWEIGHT REMOVAL CYLINDER LOWER BRACKET BOLTS ON CERTAIN 374D AND 390D EXCAVATORS
6404 7056		PI32244

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32244" 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 "PI32244" 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:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 09Oct2013 Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
30Apr2014	31Oct2014

PROBLEM

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The bolts holding the counterweight removal cylinder lower bracket need to be tightened to the required torque value on certain 374D and 390D Excavators. The actual tightening may be insufficient on certain machines, this may cause damages to the counterweight removal system.

AFFECTED PRODUCT

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Model	Identification Number
374D L	PAP00213, 215, 218-249, 251, 254-261, 263-271, 273-279, 286-288, 290, 292-299, 301-302, 304, 306-307
390D L	WBT00212-00215, 217-269, 271-280, 282-291

PARTS NEEDED

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Qty	Part Number	Description
6	7X2581	BOLT-HEX HEAD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 36% 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 NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

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 6.0-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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND RETIGHTENING THE COUNTERWEIGHT REMOVAL CYLINDER LOWER BRACKET BOLTS

MODELS INVOLVED - CERTAIN 374D AND 390D EXCAVATORS

Dear Cat Product Owner:

The bolts holding the counterweight removal cylinder lower bracket need to be inspected on the products listed below. The actual tightening may be insufficient on certain machines, this may cause damages to the counterweight removal system. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 09Oct2013 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 09Oct2013 Service Letter

Rework Procedure

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This Rework Procedure provides the instructions for inspecting and retighting the six bolts of the counterweight removal cylinder lower bracket.

The bolts are easily accessible. To access the six nuts, the counterweight has to be removed and the cylinder has to be tipped backwards.

A. Bottom Guard Removal

1. In order to access the six bolts, disassemble the rear bottom guards. Refer to Image1.2.1.

Note: Store the guards and the bolts in a safe place.

Image1.2.1

B. Counterweight Removal: Warning!

Unexpected machine movement can cause injury or death. In order to avoid possible machine movement, move the hydraulic lockout control to the LOCKED position and attach a "Do Not Operate" or similar warning tag to the hydraulic lockout control. Refer to Image1.3.1. Personal injury or death can occur from a counterweight falling during removal or installation. Do not allow personnel under or around the counterweight during removal or installation. Ensure that the lifting device is in good condition and is capable of handling the weight of the counterweight.

Make certain personnel are clear of cable when there is a load on it. Cable can break and cause personal injury. Personal injury or death can occur from a counterweight falling during removal or installation. Before you begin the Removal Procedure make sure that the support blocks are in the horizontal position.

IMPROPER OPERATION OF THE COUNTERWEIGHT REMOVAL SYSTEM CAN RESULT IN SERIOUS INJURY OR DEATH. DO NOT OPERATE THIS SYSTEM UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUAL.

When the removal cylinder is used to lower the counterweight, the counterweight can wedge against the machine frame which stops the downward movement of the counterweight. Since the removal cylinder continues to retract and the counterweight stopped, slack in the chain for the removal cylinder occurs. The counterweight can suddenly fall due to the slack in the chain which could result in personal injury or death.

Monitor the lowering of the counterweight when the counterweight is being lowered with the removal cylinder. If the removal cylinder is retracted and the downward movement of the counterweight stops, stop the lowering procedure and correct the wedging of the counterweight against the machine frame.

Image1.3.1

C. Counterweight Removal: Operations

Refer to Operation and Maintenance Manual, "Specifications" for specific weight information.

Note: If equipped, disconnect the wiring for the rear view camera before you remove the counterweight. Refer to Operation and Maintenance Manual, "Camera Harness - Disconnect and Connect", for more information.

1. Position the machine on a surface that is hard and level.

2. Position the upper structure parallel to the tracks. Lower the work tool to the ground.

3. Start the engine. Adjust the engine speed to one-third of full throttle engine speed.

4. 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.

5. Open the rear access door on the right side of the machine.

6. Place stop valves (5) in OPEN position (B). Refer to Image1.4.1.

7. Move switch (3) upward to the ON position. Refer to Image1.4.1.

8. Move control lever (4) upward in order to support the counterweight and relieve the weight on the counterweight mounting bolts. This will keep the counterweight from possibly sliding off when the counterweight mounting bolts are removed. There should be a slight tension on the chains. Refer to Image1.4.1.

Image1.4.1

9. Check the height of the sprockets in order to ensure that there is enough tension on the chains. The proper tension will ensure that the counterweight is securely supported. The height of dimension (C) should be 813mm (32inch). Refer to Image1.5.1.

Image1.5.1

10. Remove seven bolts from the cover (6). Refer to Image1.6.1.

11. Open cover (6) and lock the cover into the OPEN position. Use bar (7) in order to support the cover while the cover is in the OPEN position. Refer to Image1.6.2.

12. Remove six counterweight mounting bolts and washers.

Image1.6.1

Image1.6.2

13. Move control lever (4) upward in order to raise counterweight (8) until access to retaining pins (9) can be gained. Refer to Image1.4.1 and 1.7.1.

14. Use a ratchet wrench and an extension in order to rotate each retaining pin (9). Retaining pins (9) require 90 degrees of rotation. Retaining pins (9) are now in the UNLOCKED position.

15. Move control lever (4) downward in order to lower counterweight (8) onto supports on the ground. Refer to Image1.4.1.

16. Remove cotter pins (14). Loosen nuts (13). Refer to Image1.7.2.

17. Remove pins (12) in order to disconnect chains (11) from counterweight (8). Refer to Image1.7.2.

Image1.7.1

Image1.7.2

18. Pin (18) should be located in the storage box. Remove pin (18) from the storage box. Refer to Image1.8.1.

19. Install pin (18) into chains (11). Refer to Image1.8.1. Do not install pin bracket (18) on cylinder bracket (15).

20. At the end of pin (18), install washer (16) and bolt (17). Refer to Image1.8.1.

21. Fasten a proper rated cable with shackles to the lifting eyes on the counterweight.

22. Use an appropriate lifting device in order to put the counterweight on suitable supports.

Image1.8.1

D. Cylinder Displacement

In order to access all six nuts of the bottom bracket, counterweight cylinder (1) has to be tipped backwards. Refer to Image1.9.1.

1. Move control lever (4) downward in order to fully retract the cylinder. Refer to Image1.4.1.

2. Disconnect three hoses (26, 27, 28) that are connected to the cylinder. Place plugs on every open connection. Refer to Image1.9.2.

3. Fasten a proper rated lifting device to the cylinder; the approximate weight is about 500kg. Refer to Image1.9.3 to tie correctly.

4. Disassemble upper bracket (25). Refer to Image1.9.1.

5. Tip the cylinder backwards so the 6th nut is accessible. Ensure that the lifting device is kept in placed between the two cylinder sprockets. Secure the position by using a support. Refer to Image1.9.4.

Image1.9.1

Image1.9.2

Image1.9.3

Image1.9.4

E. Bolts Inspection and Tightening

1. Check the static torque value on each bolt, it must be higher than 1400 N.m. If this value is not reached, the corresponding bolt has to be replaced and tightened to 1600+/-200 N.m while holding nuts. Bolts must be replaced one at a time.

F. Reinstallation

Perform the procedure in reverse order.

1. Use necessary shims (22) in order to adjust the lateral clearance. Refer to Image1.9.1.

121-1891 Shim thickness: 1.0 mm (.04 inch)
127-6680 Shim thickness: 0.5 mm (.02 inch)

The tightening specification for nut (23) against nut (24): 100 +/- 20 N.m (75 +/- 15 lb ft).

2. Position the nut past the end of the bolt: 0.5 +/- 0.5mm (0.02 +/- 0.02 inch).

3. Tighten cylinder upper bracket (25) to a specified torque of 800 +/- 100 N.m. Refer to Image1.9.1.

Note: Before you install the counterweight mounting bolts, ensure that the retaining pins are in the LOCKED position and that the counterweight is securely held on the retaining pins. There should be a slight amount of slack on the chains.

4. Tighten the counterweight mounting bolts to a specified torque of 2800 +/- 350 N.m.