PRODUCT SUPPORT PROGRAM FOR REROUTING THE MAIN CONTROL VALVE HOSES ON CERTAIN 301.7D CR MINI HYDRAULIC EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REROUTING THE MAIN CONTROL VALVE HOSES ON CERTAIN 301.7D CR MINI HYDRAULIC EXCAVATORS

Usage:

TEBE5475-00

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19Jan2017

U-39

D-28

O-32

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Before/After	PRODUCT SUPPORT PROGRAM FOR REROUTING THE MAIN CONTROL VALVE HOSES ON CERTAIN 301.7D CR MINI HYDRAULIC EXCAVATORS
5057 5051		PS45362

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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 either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS45362" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

31Jan2019

PROBLEM

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The existing hose routing can allow hoses from the main control valve to rub each other and the control linkages on certain 301.7D CR Mini Hydraulic Excavators. If the existing routing allows hoses to rub each other and the controls, it can cause the hoses to wear and leak.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
301.7D CR	LJ800151-00155, 157-186, 200-229, 231, 234, 237-572, 574, 577, 579, 601-638 LJD00150, 153, 156, 158-188, 199-232, 234-242, 245-257, 300-302, 307, 310-377, 379-381, 385-416, 420-421, 424, 426-427, 430, 436-466, 470-476, 479-480, 483, 486, 490-491, 493-497, 500-504, 506-507, 509-510, 512-514, 516-591, 594-623, 625-648, 650-666, 668, 670-699, 702, 704-705, 707, 710-728, 731-740, 742-831, 836, 838-839, 841-849, 856-861, 864-876, 878-896, 898-901, 904-905, 907, 922, 924-925, 927-929, 940-957, 961-975, 977-1014, 1020-1055, 1057-1085, 1098-1101, 1103-1119

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*******Group 2*******

301.7D CR

LJ800230, 232-233, 235-236

LJD00155, 189-198, 233, 243-244, 303-306, 308-309, 378, 382-384, 417-419, 422-423, 425, 428-429, 431-435, 467-469, 477-478, 481-482, 484-485, 487-489, 492, 498-499, 505, 508, 511, 515, 592-593, 624, 649, 667, 669, 700-701, 703, 706, 708-709, 729-730, 741, 832-835, 837, 840, 850-855, 862-863, 877, 897, 902-903, 906, 908-921, 923, 926, 930-933, 935-939, 958-960, 976, 1015-1019, 1056, 1086-1097, 1102

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	5102545	KIT-REPAIR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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.
*****Group 2*****
1	5102550	KIT-REPAIR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-1000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-3000 hrs, 37-48 mo	33.0%	50.0%	0.0%	50.0%	50.0%	0.0%

NOTE: This is a 4.0-hour job for Group 1
Note: The Before Failure and After Failure procedures are the same. Resultant damage will include, but is not limited to, replacing any additional hoses from the control valve that are damaged. Note: An additional $15 US Dollars is allowed for one US gallon of hydraulic fluid for both Before Failure and After Failure rework.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-1000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-3000 hrs, 37-48 mo	33.0%	50.0%	0.0%	50.0%	50.0%	0.0%

NOTE: This is a 3.5-hour job for Group 2
Note: The Before Failure and After Failure procedures are the same. Resultant damage will include, but is not limited to, replacing any additional hoses from the control valve that are damaged. Note: An additional $15 US Dollars is allowed for one US gallon of hydraulic fluid for both Before Failure and After Failure rework.

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

Note: 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 Operation and Maintenance manual, for your machine, in order to release system pressure.

Preparation for Rework of the Machine:

- Park machine on level ground and secure machine from rolling.
- Stop the engine.
- Connect a vacuum pump to prevent fluid loss.
- Open the engine cover and remove the side cover.
- Remove the floor plate. Refer to Image1.1.1.

Image1.1.1

Replacement of the Head End Bucket Cylinder Hose (Group 1 only):

For machines equipped with a long stick and Bucket Flow Diverter Lines only (machines in Group 1), replace the 438-7805 Head End Bucket Cylinder Hose with a new 499-7283 Hose Assembly.

1. Remove the 107-0269 Bolt, 379-2547 Plate, and 379-2612 Clamp. Refer to Image1.2.1.

Image1.2.1

2. Loosen the existing 438-7805 Head End Bucket Cylinder Hose from the fitting on the bucket cylinder.

3. Loosen the bucket cylinder hose from the fitting on the main control valve and remove the existing 438-7805 Head End Bucket Cylinder Hose. Refer to Image1.3.1.

Image1.3.1

4. Replace the 438-7805 Head End Bucket Cylinder Hose with new 499-7283 Hose.

5. Re-install the 107-0269 Bolt, 379-2547 Plate, and 379-2612 Clamp.

Replacement of Fitting - Machines with Second Auxiliary Valve Only:

1. For machines equipped with a second auxiliary valve, replace the 373-5654 Fitting at the control valve with longer new 436-8945 Adapter. Refer to Image1.5.1.

Image1.5.1

Adjustment of the Hoses at the Main Control Valve:

1. Loosen the hydraulic fittings on the control valve and angle the couplings to the right such that there is at least 10mm clearance to the travel and swing control linkages. Refer to Image1.6.1.

Image1.6.1

Addition of Bracket and Hose Clamp:

1. Mark two holes in 434-2998 Bracket. Refer to Images1.7.1 and 1.7.2.

Image1.7.1

Image1.7.2

2. Position 504-6742 Bracket (26) based on the hole locations in Step 1 and confirm hole locations. Drill two 9mm holes after location is confirmed. Refer to Image1.8.1.

Image1.8.1

3. Assemble 504-6742 Bracket (26) with two new 7X-2537 Bolts (30), four new 8T-4224 Washers (31), and two new 3T-0852 lock nuts. Assemble the wiring harness with a new 372-7358 Clip (29), as shown. Refer to Images1.9.1 and 1.9.2.

Image1.9.1

Image1.9.2

4. Add new 504-6744 Hose Guard (28) over hoses and fasten loosely to the bracket with new 504-6743 Bracket (27), and 3T-0852 Lock Nuts (19). Refer to Image1.10.1.

Note: Machines without second auxiliary lines will also require 504-6745 Plate (32).

Image1.10.1

5. Fully extended the boom cylinder (this will require lowering the front linkage below the level of the tracks) and retract the boom swing cylinder to move the boom all the way to the right of the cab. Ensure that the hose guard must extend away from the bracket 10 to 15mm. Refer to Image1.11.1.

Image1.11.1

6. Tighten the nuts without a washer to the end of the threads on plate (27).

7. Add new 510-2549 Spiral Hose Guard over swing hoses to prevent chafing on the swing motor, chassis, and threaded fittings. Use about 1m per hose. Refer to Image1.12.1.

Image1.12.1

Reposition of the Travel Alarm:

If the machine is equipped with a travel alarm, the travel alarm must be relocated.

1. Drill two 7mm holes in 434-3005 Plate. Refer to Image1.13.1.

Image1.13.1

2. Reposition the travel alarm 37mm to the right on the floor plate. To prevent chafing, the travel alarm cable must not touch the hose bracket.

Group Number 2

For machines in Group 2, follow the same procedures as Group 1 except Steps 1 through 5 in the section "Replace the head end Bucket Cylinder Hose (Group 1 only)". This entire step is not needed.