PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FAN PUMP CONTROL VALVE ON CERTAIN D8T AND D9T TRACK-TYPE TRACTORS EQUIPPED WITH WASTE HANDING OR WOODCHIP ARRANGEMENTS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FAN PUMP CONTROL VALVE ON CERTAIN D8T AND D9T TRACK-TYPE TRACTORS EQUIPPED WITH WASTE HANDING OR WOODCHIP ARRANGEMENTS

Usage:

REBE2551-00

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26Oct2007

U-540

A-441

D-440

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FAN PUMP CONTROL VALVE ON CERTAIN D8T AND D9T TRACK-TYPE TRACTORS EQUIPPED WITH WASTE HANDING OR WOODCHIP ARRANGEMENTS
5070 5455		PI31383

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31383" 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 "PI31383" 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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COMPLETION DATE	TERMINATION DATE
30Apr2008	31Oct2008

PROBLEM

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On certain D8T and D9T Track-Type Tractors equipped with Waste Handling or Woodchip arrangements, the cutoff pressure adjustment screw on the fan pump control valve can wear. This wear can cause the cutoff pressure to drift down significantly. This lower cutoff pressure can reduce the maximum fan speed and possibly lead to system overheating.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
D8T	J8B00277, 313, 366, 368, 376, 417, 612, 665, 936, 939, 1139 KPZ00339, 352, 364, 376, 378, 380, 387-388, 390, 407, 409-410, 420, 435-436, 438, 441, 443, 446, 448-450, 462, 493, 508, 512, 552, 560, 575, 588, 591, 597, 608, 617-618, 623, 639-640, 645, 649, 651, 666, 676, 680-682, 687, 705, 710, 715-717, 723, 729-730, 732, 748, 750, 754, 762, 771, 777-778, 788, 790, 794, 796, 836, 842-843, 846, 870-871, 889, 895, 906-908, 934-935, 937, 942-943, 972, 978, 993, 995, 998, 1004, 1015, 1019, 1031-1033, 1052, 1054, 1060, 1067, 1075, 1083, 1087-1088, 1099, 1107, 1115, 1119, 1139, 1141, 1143, 1146, 1155, 1164, 1166, 1168, 1184, 1187, 1191, 1212, 1215, 1219, 1223, 1228, 1230, 1236-1238, 1265-1267, 1271, 1290, 1293, 1295-1296, 1301-1304, 1317, 1320, 1323-1324, 1353, 1370-1371, 1374, 1376, 1379, 1410, 1429, 1434, 1436-1437, 1443, 1452-1453, 1488, 1498, 1505-1506, 1509, 1521, 1525, 1535, 1540, 1558-1559, 1569-1570, 1615, 1624, 1627-1634, 1636-1637, 1649-1650, 1654-1655, 1666-1667, 1693-1694, 1713, 1734, 1743, 1753, 1772-1773, 1807, 1809, 1838-1839, 1874, 1887-1888, 1898, 1902, 1929, 1943-1944, 1957, 1962-1963, 2016, 2042, 2066, 2071, 2087-2088

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*****Group 2*****
D9T	RJS00119-00120, 157, 190, 199, 210-211, 236, 247, 259, 290, 297, 306-307, 309, 330, 357, 366, 374, 381, 385, 391, 393, 401, 404-405, 449-450, 456, 473, 476, 500, 509, 518, 569, 597-598, 601, 608, 611, 624, 640, 655, 675, 680, 687, 697, 717-719, 733, 736, 739, 763, 768, 779-780, 782, 792, 806-808, 826, 833, 844

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
3	9X7680	SEAL-O-RING
1	3151525	KIT-ADJUSTER
*****Group 2*****
3	9X7680	SEAL-O-RING
1	3151525	KIT-ADJUSTER

ACTION REQUIRED

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NOTE: If Service Letters PI31275 and PI31342 have not been performed yet, apply this Service Letter in conjunction with them.

The fan pump control valve needs to be reworked on certain D8T and D9T Track-Type Tractors equipped with Waste Handling or Woodchip arrangements to install a cutoff pressure adjustment screw with a hardened tip to prevent wear.
Remove the 2290890 Fan Pump Control Valve from the fan pump.
Remove the cutoff adjust screw from the 2290890 Control Valve and install the new 3151525 Cutoff Adjuster Kit.
Install the reworked control valve on the fan pump with three new 9X7680 Seals.
Test and adjust the fan control to the new cutoff and standby pressure specifications.

Refer to the Service Manual and the attached Rework Procedure.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 2

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.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FAN PUMP CONTROL VALVE ON CERTAIN D8T AND D9T TRACK-TYPE TRACTORS EQUIPPED WITH WASTE HANDING OR WOODCHIP ARRANGEMENTS

MODELS INVOLVED - D8T and D9T Track-Type Tractors

Dear Caterpillar Product Owner:

The fan pump control valve needs to be reworked on the products listed below. The cutoff pressure adjustment screw on the existing fan pump control valve can wear. This wear can cause the cutoff pressure to drift down significantly. This lower cutoff pressure can reduce the maximum fan speed and possibly lead to system overheating. The fan pump control valve needs to be reworked to install a cutoff pressure adjustment screw with a hardened tip to prevent wear. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 26Oct2007 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 26Oct2007 Service Letter

Rework Procedure

1. Refer to the D8T or D9T Service Manual Disassembly and Assembly (D8T-RENR7480, D9T-RENR7470), section "Hydraulic System Pressure ? Release" to place the machine in the service position and release the hydraulic oil pressure in the system.

2. Refer to the D8T or D9T Service Manual Disassembly and Assembly (D8T-RENR7480, D9T-RENR7470), section "Piston Pump (Hydraulic Fan) - Remove" to access the fan pump on the tractor.
NOTE: The pump does not need to be removed from the tractor.

3. Refer to D8T or D9T Service Manual Disassembly and Assembly (D8T-RENR7480, D9T-RENR7470), section "Piston Pump (Hydraulic Fan) - Disassemble", to remove the control valve from the pump.

4. Locate the cutoff pressure adjust screw on the control valve using Image 1.4.1

Image 1.4.1
(1) Cutoff Pressure Adjust Screw Locknut
(2) Cutoff Pressure Adjust Screw
(3) Cutoff Pressure Adjust Screw Gland Nut
(4) Port T
(5) Spring Retainer
(6) Standby Pressure Adjust Screw

Image1.4.1

5. Measure the length L of the adjust screw protruding beyond the gland nut, as shown in Image 1.5.1

Image 1.5.1 - Cutoff Pressure Adjust Screw Length L

Image1.5.1

6. Place the control valve vertically in a vice, with the cutoff adjust screw pointing up, and remove the complete cutoff adjust screw assembly by loosening the gland nut using a 17 mm box wrench.

7. Install the new cutoff adjuster kit 315-1525 by putting Loctite 603 on the thread of gland nut and tightening it to 25 N.m (18 ft.lbs). While tightening the gland nut, look through port T to ensure that the tip of the adjust screw properly engages the spring retainer. The tip of the adjust screw should be completely seated in the bottom of the spring retainer.

8. Loosen the locknut with a 10 mm box wrench and turn the adjust screw with a 2.5 mm Allen wrench until the screw length protruding from the gland nut matches to length L measured on the old cutoff adjust screw. Then tighten the locknut to 10.4 N.m (7.5 ft.lbs).

WARNING: Adjust screw length L should never be shorter than 10.5 mm. Under 10.5 mm, the o-ring on the adjust screw will start to protrude into passage A (see Image 1.8.1).

NOTE: With the adjust screw at a length of 10.5 mm, the cutoff pressure will be around 30000 kPa (4351 psi).

Image 1.8.1
(1) O-Ring
(2) Passage A

Image1.8.1

9. Refer to D8T or D9T Service Manual Disassembly and Assembly (D8T-RENR7480, D9T-RENR7470), section "Piston Pump (Hydraulic Fan) - Assemble", to install the rebuilt control valve on the pump, using 3 o-ring seals 9X-7680.

10. Adjust the fan pump cutoff and standby pressures to the new specifications shown in Image 1.10.1 using the D8T or D9T Service Manual Testing and Adjusting (D8T-RENR7527, D9T-RENR7532) sections "Test Procedure (Maximum Mechanical High Pressure)", "Adjustment Procedure (Maximum Mechanical High Pressure)", "Test Procedure (Minimum Pump Pressure)" and "Adjustment Procedure (Minimum Pump Pressure)".

WARNING: Verify that a fan with 26? blade pitch has been installed on the machine according to service letters PI31275 or PI31342 before adjusting cutoff pressure to the new specifications. The fan part number is stamped on front side of a blade near the tip.

WARNING: The cutoff pressure adjust screw is VERY sensitive. It has a 15000 kPa per turn ratio (2175 psi/turn). If the cutoff pressure reaches 30000 kPa (4351 psi), the adjust screw o-ring seal will protrude into passage A and it could get cut, leading to contamination and incorrect valve operation.

NOTE: The standby adjust screw has a 1600 kPa per turn ratio (232 psi/turn).

Image 1.10.1