PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LEVER ASSEMBLY CONTROL ON THE REAR PUMP ON CERTAIN 390F EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LEVER ASSEMBLY CONTROL ON THE REAR PUMP ON CERTAIN 390F EXCAVATORS

Usage:

TEBE5335-02

Show/hide table

16Mar2017

(Revised 10May2017)

U-147

A-96

D-115

O-117

Show/hide table

Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LEVER ASSEMBLY CONTROL ON THE REAR PUMP ON CERTAIN 390F EXCAVATORS
5070		PI32747

Show/hide table

NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32747" 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 "PI32747" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 16Mar2017 (Revised 27Apr2017) Service Letter. Changes have been made to the Rework Procedure to include additional steps and images.

Show/hide table

COMPLETION DATE	TERMINATION DATE
30Sep2017	31Mar2018

PROBLEM

Show/hide table

The lever assembly on the rear pump can fail on certain 390F Excavators. If the existing lever assembly fails, it can cause additional pump damage.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
390F	GAY00156-00223, 10001-10027 HJD00231-00238, 10001-10024 HSM00283-00306 TYE00131-00223
390F L	FEH00211-00214, 10001-10017, 10020-10023, 10025-10034 MGF00157-00359, 10001-10003, 10008 P4J90200-90201
390F L OEM	N6400101-00105
390F OEM	PT700101-00102

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	4586030	ROTATING GP -A (After Failure Only)
1	4649278	GASKET (After Failure Only)
1	4649758	GASKET
1	5249271	LEVER AS-CONTROL
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

Show/hide table

Refer to the attached Rework Procedure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

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

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.5-hour job
Note: 2.5 hours is allowed for a Before Failure repair. Up to 36.0 hours is allowed for an After Failure repair. This would require removal of the pump from the machine and full disassembly/assembly.

PARTS DISPOSITION

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

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

Show/hide table

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LEVER ASSEMBLY CONTROL ON THE REAR PUMP

MODELS INVOLVED - CERTAIN 390F EXCAVATORS

Dear Cat Product Owner:

The rear lever on the main hydraulic pump needs to be replaced on the products listed below. The existing lever can break and cause pump failure. 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 16Mar2017 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 16Mar2017 Service Letter

Rework Procedure

Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Refer to the Service Manual if/as necessary.

Refer to the Operation and Maintenance manual, for your machine, in order to release system pressure.

Note: Do NOT install the two springs that are part of 524-9271 Lever Assembly, for this Service Letter Rework Procedure there is no need to replace springs.

Note: If the 524-9271 Lever Assembly roller is not attached to the measurement piston, please attach.

Image1.1.1

Attach Measurement Piston:

1. Fit measurement piston into bushing. It has to be positioned with the two milled surfaces into the contour of the bushing, to guarantee a good guidance. Refer to Image1.2.1.

2. Check position if measurement piston is firmly in position in the bushing and fits full in shape.

Image1.2.1

3. Place the bushing (small end side) on a flat and clean surface. Refer to Image1.3.1.

Image1.3.1

4. Place the roller onto the two fixing holes of the measurement piston. Refer to Image1.4.1.

Image1.4.1

5. Use a plastic hammer to assemble it with light strokes onto the roller.

6. Check position if roller is firmly in position and fits full in shape.

Installation of the Control Lever Assembly:

1. Install Tooling (A) onto the hydraulic tank. Attach an air supply to Tooling (A). Apply 345 +/- 69 kPa (50 +/- 10 psi) of air. This procedure will pull a vacuum on the hydraulic system. Refer to Images1.6.1 and 1.6.2.

Image1.6.1

Image1.6.2

2. Label the hoses before disconnecting. Disconnect the following hoses: Cross-sensing, NFC and Powershift, on the controller. Refer to Image1.7.1.

Image1.7.1

3. Loosen the four Allen screws of the regulator and remove the regulator. Pay attention to the gasket and locating pin. Refer to Image1.8.1.

Image1.8.1

4. Remove the existing gasket. Refer to Image1.9.1.

Image1.9.1

5. Replace the existing lever with a new 524-9271 Control Lever Assembly. In order to hold the piston in position in the lever use petroleum jelly, then push the spring to insert the lever and ensure that the spring is positioned on the lever. Refer to Image1.10.1 and 1.10.2.

6. Install a new gasket ensuring that it is thoroughly seated on the location pin.

Image1.10.1

Image1.10.2

7. Reposition the controller on the pump, ensure that the lever is inserted into the hole of the actuator piston pump. Then, move the control to the position opposite the mounting holes. Be careful not to damage the contact face on the pump. Refer to Image1.11.1.

Image1.11.1

8. Insert the Allen screws and tighten to a specified torque of 15.5 N.m. Refer to Image1.12.1 and 1.12.2.

Assembly of Regulator and Feedback on Pump:

a. Put new seal (1) on control valve (3).

b. Preassemble new feedback (4) into the groove of control valve (3). Push back feedback springs (5), using a screw driver or an other suitable tool (do not damage the flat gasket). Take care that feedback springs ((5) are positioned properly onto the spring retainer of feedback (4).

c. Take the regulator, including the pre-assembled feedback, and push the feedback into the bore of counter piston (6) of the pump. Take care that the feedback is positioned correctly in counter piston (6).

NOTE: Do not interchange the longer feedback lever on the rear pump with the shorter feedback lever of the front pump.

d. Push control valve (3) in the direction against feedback springs (5), until cylinder pins (7) slide into the bores of the pump housing, (Do not damage the sealing surface of the pump housing).

e. Insert mounting bolts (2) crosswise by hand and then tighten the bolts to a specified torque of 15.5 N.m.