PRODUCT SUPPORT PROGRAM FOR REPLACING THE VALVE SECTION OR SPOOL ON CERTAIN 930G SMALL WHEEL LOADERS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REPLACING THE VALVE SECTION OR SPOOL ON CERTAIN 930G SMALL WHEEL LOADERS
Usage:
REBE2571-00
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20Dec2007
U-678
A-547
D-550
O-590
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After Failure Only
PRODUCT SUPPORT PROGRAM FOR REPLACING THE VALVE SECTION OR SPOOL ON CERTAIN 930G SMALL WHEEL LOADERS
5051
PS51425
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NOTE:
This Program can only be administered after a failure occurs.
The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51425" as the Part Number
and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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
31Dec2009
PROBLEM
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The existing hydraulic system may exhibit instability in the tilt circuit that results in shaking of the bucket or work tool when performing a dump operation on certain 930G Wheel Loaders. This instability may result in unintentional operator movement generally referred to as "Dump Shudder".
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 0% of dealership population. This is an inital order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 0% of dealership population. This is an inital 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
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-5000 hrs
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 1
If the valve section needs to be replaced, 8 hours of labor is allowed.
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Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-5000 hrs
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 8.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Group Number 1
Original 930G implement valves were built in a select-fit manner, meaning that each valve spool was ground to fit an individual valve bore to provide adequate spool to bore clearance. Valve bodies were then stamped with a corresponding 2-digit bore code to identify this select fit. Starting in January 2007, valve bore machining improvements were made that provided much tighter control and allowed 930 implement valves to be built in a random-fit manner. Spools no longer had to be ground for an individual bore, and bore codes were no longer stamped in valve bodies. As the rework contained in this service letter is performed it is imperative that adequate spool to bore clearance be maintained by properly matching the new spool size to the valve bore.
*** NOTE: Roughly 95% of 930 machines in Group 1 can be reworked with a simple spool kit. The other approximately 5% will have to be reworked like those machines in Group 2 with a complete tilt section. If after following the steps outlined below there is any doubt regarding proper spool to bore fit, error on the side of caution and replace the complete tilt section with 311-8279 as per Group 2 instructions.
BEFORE GOING TO CUSTOMER SITE: Order spool kit 319-1728.
BEFORE BEGINNING: Park machine on level ground, engage parking brake, lower bucket to ground, install articulation lock, and shut machine down. Then release trapped cylinder pressure by turning the key to the ON position and cycling all controls.
STEP 1: Remove steel implement valve cover on machine right hand side.
STEP 2: Identify the 2-digit bore code stamped in the casting on the machine front side of the tilt section work port face, as represented by the green dot in Image 1.1.1 below. The opposite side may have a 3+ digit stamping that is a serial number and not the bore code. Make sure you read the 2-digit code. On some valves, the 2-digit bore code may be on the machine rear side of the work port face instead (blue dot in Image 1.1.1). Note that Image 1.1.1 shows the implement valve as viewed from inside the machine, looking out. Figure 1.1.2 shows a photo of an actual bore code stamped into a valve section.
NOTE: If a bore code is not visible, thoroughly clean both sides of the valve, lightly sand away paint in both areas on the work port face identified above and closely re-inspect, as bore code stamp depth and paint thickness may prevent the code from being clearly visible.
Image1.1.1
Image1.1.2
STEP 3: Locate 2-digit bore code number in the chart below and identify corresponding spool. If bore code is not within range (i.e., less than 42 or greater than 51), a Tilt section change is required - refer to rework instructions for Group 2. If no bore code can be found, and the thorough examination described in Step 2 above has been performed, use spool 319-1725-A unless machine serial number is prior to TWR02850, in which case a Tilt section change is required ? see Group 2 instructions.
If bore code is 49, 50, 51 use spool 319-1725-A. If bore code is 46, 47, 48 use spool 319-1726-B If bore code is 42, 43, 44, 45 use spool 319-1727-C No 2-digit code and serial # > TWR02850 use spool 319-1725-A
STEP 4: Pull vacuum on the hydraulic system.
STEP 5: Loosen and rotate pilot line on machine front side of tilt section up to gain access to end plug. Retighten pilot line.
STEP 6: Remove 240-1867 spool end plug on tilt section with 1.5 inch socket and pull out assembly, which should include 2 springs and the plug, as seen in Image 1.1.3 below.
Image1.2.1
STEP 7: Remove spool and spring retainer (see Image 1.1.4 below).
Image1.3.1
STEP 8: Transfer spring retainer from old spool to new spool.
STEP 9: Insert new spool with old spring retainer in valve bore, ensuring that spool end with the ball plug (as shown in Image 1.1.5) is oriented towards machine rear. The plain smooth end should be towards machine front, as shown in Image 1.1.6. Reassemble springs and end plug.
Image1.4.1
Image1.4.2
STEP 9: Retighten end plug to 200 N-m and loosen and rotate pilot line back to original position, and then torque to 25 N-m.
STEP 10: Perform five racks and dumps ranging from neutral to full modulation to verify smooth operation with no sticking.
STEP 11: Reinstall implement valve cover and torque bolts.
STEP 12: Check machine hydraulic oil level and top off if necessary.
Group Number 2
Replace entire implement valve tilt section with 311-8279 Valve Tilt Section per Disassembly and Assembly Manual, RENR8730.
