The Hydraulic Pump Control System Needs To Be Upgraded On Certain 5230 Excavators Caterpillar

The Hydraulic Pump Control System Needs To Be Upgraded On Certain 5230 Excavators

Usage:

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Caterpillar: Confidential Yellow

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3208" as the Part Number, "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 "PI3208" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the November 25, 1998 Service Letter. Changes have been made to the Parts Needed and Rework Procedure.

Completion Date

May 31, 1999

Termination Date

November 30, 1999

Problem

The current stand alone GLB pump control system on 5230 Excavators is difficult to adjust and obtain optimal, consistent performance. The GLB is also prone to damage from harness problems, and moisture, water or dirt ingress. The new integrated proprietary underspeed system improves pump control calibration and response. The new software control is resident in the engine control personality module.

Affected Product
Model & Identification Number

5230 (7LL21-62)

Parts Needed

Dealers will need to order parts for this Program.

1 - 5F0304 PLUG-DRAIN

1 - 3J1907 SEAL

1 - 3J7354 SEAL-O-RING ^*

1 - 5P7468 CLIP

1 - 5P7469 CLIP

30 - 3S2093 STRAP-CABLE

1 - 8T4121 WASHER-PLATE

1 - 8T7087 GROMMET

3 - 6V8397 SEAL-O-RING^*

1 - 6V8781 Tee

1 - 6V9850 ELBOW-SWIVEL^*

56 - 9X6772 STRAP-CABLE

1 - 1316802 TUBE AS

1 - 1340426 SENSOR GP-PR

1 - 1356681 HARNESS AS

1 - 1356682 HARNESS AS

1 - 1357832 HARNESS AS

1 - 1358056 PANEL

1 - 1414614 CONT GP

1 - 1415746 SENSOR GP-PR

1 - 1419321 PLATE AS

1 - 1435119 HARNESS AS-W

1 - 1493006 ADAPTER AS^*

^*Use only if required.See Rework Procedure for instructions.

NOTE: In addition, the update will require a new VIMS config file and or source file. See the rework procedure to identify the correct files.

NOTE: Completion of the update requires a laptop computer equipped with VIMS PC Software. You will also need ET software for calibration.

Action Required

See the attached procedure.

Owner Notification

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

Service Claim Allowances

NOTE: This is a 40-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

CAB

1. Remove existing 118-0638 Switch, 110-8338 Knob, 3T-4405 Switch, 3E-5169 Guard, and AESC rocker switch from the left hand console as shown in Illustration 1. Remove 120-0411 jumper harness connecting 118-0638 Power Mode switch to left hand console main harness.

2. Replace existing left hand console Harness As. with 135-6682 Harness As. shown in Illustration 2.

3. Replace existing 119-9521 Plate with 135-8056 Plate shown in Illustration 2.

4. Reinstall AESC rocker switch into 135-8056 Plate.

5. Remove existing 7T-4003 resistors (2) and 120-7628 jumper wire or 143-3215 resistor from bracket located at upper left corner of fuse box, as shown in Illustrations 3 & 4.

CAB SUPPORT

6. Remove 100-5075 Control Gp, 124-8587 Control, and all mounting hardware shown in Illustration 5.

7. Replace the current cab support harness with (1) 135-6681 Harness As. shown in Illustration 5. Use (15) 7K-1181 Straps as required for installation.

NOTE: Remove the code plug from the old cab support harness and install the code plug in the new cab support harness.

ENGINE COMPARTMENT

8. Remove existing engine harness and replace with 143-5119 Harness As. Refer to PS4178 if engine shut-off switch is mounted on the engine.

9. Secure new engine harness with (56) 9X-6772 Straps as shown in Illustration 6-8.

10. Remove 3E-7886 engine speed sensor from flywheel housing shown in Illustration 9. Install (1) 5F-0304 Plug and (1) 4B-8407 gasket.

11. Remove existing Personality Module (chip) from engine control module (ECM) and install 141-4614 Chip (refer to Illustration 10):

a. Turn off main battery disconnect switch.

b. Loosen hose clamps on fuel lines running to ECM.

c. Remove mounting hardware holding ECM to 117-0054 Bracket.

d. Pull ECM away from engine.

e. Remove Personality Module Cover.

f. Remove Personality Module and discard.

g. Install (1) 141-4614 Personality Module

h. Install Personality Module Cover.

i. Install ECM to 117-0054 Bracket using existing hardware.

j. Tighten hose clamps on fuel lines running to ECM.

12. Install a new 141-5746 Air Pressure Sensor as shown in Illustration 11 & 12.

13. Replace existing main pump compartment harness (harness connected to the solenoids that runs along the top of the fire wall) with 135-7832 Harness As. Secure with (30) 3S-2093 Straps. Connect the new harness to the solenoids as shown in Illustration 13.

14. Do Step 14 part A and B for machines with one valve block and one power shift solenoid.

a. Install (1) 134-0426 Power Shift Pressure Sensor as shown in Illustration 13:

(1) 8T-4136 Bolt

(1) 8T-7087 Grommet

(1) 5P-7468 Clip

(1) 5P-7469 Clip

b. Install the following hardware as shown in Illustration 13.

(1) 6V-9850 Elbow (if not already installed)

(1) 131-6802 Tube (if not already installed)

(1) 3J-7354 Seal

(1) 149-3006 Adapter

15. Do Step 15 part A through C for machines with two valve blocks and one power shift solenoid.

a. Install (1) 134-0426 Power Shift Pressure Sensor as shown in Illustration 14.

b. Connect the power shift pressure sensor to the power shift solenoid with (1) 3J-7354 Seal, (1) 149-3006 Adapter as shown in Illustration 14.

c. Go to Step 17.

16. Do Step 16 part A through G for machines with two valve blocks and two power shift solenoids

a. Install (1) 134-0426 Power Shift Pressure Sensor as shown in Illustration 15.

b. Remove the pump signal line from the bottom of one of the power shift solenoids. Remove the line above the pressure tap. Remove the adapter and seal from the bottom of the power shift solenoid.

c. Install (1) 6V-8781 Tee and (1) 3J-1907 Seal in the bottom of the power shift solenoid. Connect the pressure tap and the pump signal line to the tee.

d. Install (1) 6V-9850 Elbow and (1) 6V-8397 Seal to the tee.

e. Install (1) 131-6802 Tube Assembly and (1) 6V-8397 Seal to the assembly.

f. Connect the power shift pressure sensor to the adapter with (1) 3J-7354 Seal.

g. Go to Step 17.

VIMS

17. Refer to the chart on Illustration 16. Locate the current VIMS source and configuration code from the appropriate columns. Replace these codes with the proper new VIMS source and configuration code.

POWER SHIFT SOLENOID (CAT UNDERSPEED) CALIBRATION

1. "Key on" and wait for 30 seconds for ECM to reprogram itself. Start the engine. (if not already done)

2. Perform various implement functions to warm up the machine and to remove entrapped air from powershift pressure hydraulic circuit.

3. Connect the ET service tool to the service connector in the cab. Plug into the extension of the 7X-1570 cables.

4. Select "Service...Calibrations...Power Shift Pressure Solenoid Calibration" from the ET Main Menu Bar. Select the Start button. Note the ECM will control Speed during this operation. This will take about one to two minutes to complete. Watch the ET screen for information regarding the finish of the calibration.

5. It should say Calibration Successful. If not it will give one of several reasons.

a) Machine was moved. Caused by throttle switch AESC Enable Switch, AESC Resolver switch being changed or activated. Also if speed falls outside of 1810 ± 15 RPM at upper point or 725 ± 15 RPM at lower point.

b) Active Diagnostic. Caused by active diagnostics on Power Shift Pressure Sensor, Solenoid, or Throttle Switch. If this happens your only choice is to fix problem.

c) Hydraulic Circuit not responding. Caused by the Power Shift pressure sensor responding to changes in current on the Power Shift Solenoid. Note: If this occurs the signals are OK electrically. Look for leaks in the hydraulic circuit or plugged lines etc. If you see the Hydraulic Circuit Not Responding condition try the test again.

d) Engine Not running. The engine was not running or stopped running during the procedure. Make sure the engine is running before starting this procedure.

These are the valid reasons for the calibration to fail. If it does not fail you will see "Calibration Successful". To validate the calibration check the status screens on ET (v 1.5 or later) and verify that:

- at 1810 RPM the Power Shift Pressure is at 2450 kPa +/- 150 kPa.

- and at 725 RPM the Power Shift Pressure is at 800 kPa +/- 150 kPa.

Illustration 1.