Replace The Drum Propel Pump On Certain CP533, Parts Stock CS533, CP563, CS563, And CS583 Compactors Caterpillar

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1234" 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 "PI1234" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from Parts Stock as soon as possible.

NOTE: This revised Service Letter replaces the January 31, 1994 Service Letter. Changes have been made to the Affected Product, Parts Needed, action required, service claim allowances, and parts disposition.

Problem

The side cover of the drum propel pump may wear causing a failure of the swashplate leveler assembly on certain CP533, CS533, CP563, CS563, and CS583 Compactors. If this occurs, the machine may move forward while the propel handle is in the neutral position.

Affected Product
Model & Identification Number

Group 1

CS563 (8XF661-669, 8XF671-680, 8XF682-733, 8XF735-778); (7GG256-258, 7GG260-260, 7GG261-261, 7GG263-263, 7GG276-276, 7GG278-278, 7GG280-290, 7GG307-309, 7GG320-320, 7GG321-321, 7GG323-324, 7GG327-327, 7GG328-328, 7GG330-333, 7GG339-339, 7GG348-348, 7GG349-349, 7GG350-359, 7GG365-368 , 7GG370-370, 7GG371-371)

CP563 (1YJ331-373, 1YJ376-382); (5AJ71-73, 5AJ75-81, 5AJ88-88, 5AJ89-89, 5AJ91-91, 5AJ92-92, 5AJ101-105)

Group 2

CP533 (3ZL26-26, 3ZL27-27)

CS533 (3BL26-62, 3BL64-91); (4HL26-39)

CP563 (1YJ387-390); (5AJ106-107, 5AJ110-111)

CS563 (8XF779-822, 8XF824-846, 8XF848-851, 8XF853-873, 8XF875-875, 8XF878-883, 8XF885-885, 8XF891-904, 8XF906-906, 8XF911-911)

CS583 (8YJ118-125, 8YJ127-140); (1EL133-140, 1EL145-145, 1EL149-149, 1EL150-150, 1EL155-155, 1EL157-157)

Parts Needed

Dealers will need to order parts for this Program.

Pump Inspection Only

2 - 6V8397 Seal-O-Ring

2 - 6V8398 Seal-O-Ring

2 - 6V9746 Seal-O-Ring

Pump Inspection And Pump Update

1 - 4C8498 Plate (See Note Below)

4 - 3D2824 Seal-O-Ring

1 - 5E8771 Seal-O-Ring

1 - 5E8769 Seal-O-Ring

1 - 1G5129 Gasket

1 - 1G8878 Filter

2 - 3J1907 Seal

1 - 3J7354 Seal-O-Ring

1 - 4J0519 Seal-O-Ring

2 - 4J5267 Seal-O-Ring

1 - 4J5477 Seal-O-Ring

2 - 3K0360 Seal

1 - 5K9090 Seal-O-Ring

2 - 2M9780 Seal-O-Ring

1 - 7M8485 Seal

1 - 5P2931 Seal-O-Ring

1 - 6R1530 Gasket

2 - 7R3437 Seal Nut

1 - 2S4078 Seal

1 - 6V5778 Seal-O-Ring

1 - 6V7350 Seal-O-Ring

3 - 6V8397 Seal

4 - 6V8398 Seal-O-Ring

4 - 6V9746 Seal-O-Ring

1 - 7X5494 Seal-O-Ring

1 - 1084572 Leveler

1 - 1172849 Side Cover

6 - 1176017 Screw

NOTE: One 4C8498 Plate is required for reassembly of the pump assembly.Order only one plate per store.If upon disassembly of the 1G8279 or 1G9720 Pump Group, it is found that the leveler arm has broken, the complete pump group should be replaced with a 0R4479 Pump Group.

Pump Inspection And Pump Replacement (If The Leveler Arm Of The Propel Pump Group Is Broken)

4 - 3D2824 Seal-O-Ring

1 - 1G8878 Filter

2 - 3J1907 Seal

1 - 3J7354 Seal-O-Ring

1 - 4J0519 Seal-O-Ring

2 - 4J5267 Seal-O-Ring

1 - 4J5477 Seal-O-Ring

2 - 3K0360 Seal

1 - 5K9090 Seal-O-Ring

2 - 2M9780 Seal-O-Ring

1 - 0R4479 Pump Group (see note below)

3 - 6V8397 Seal-O-Ring

4 - 6V8398 Seal-O-Ring

4 - 6V9746 Seal-O-Ring

NOTE: Affected Products in Group 1 use a 1G8279 Pump Group.Affected Products in Group 2 use a 1G9720 Pump Group.When replacing the existing 1G8279 Pump Group with the 0R4479 Pump Group on Affected Products in Group 1, the 7R3386 Drive Coupling (a part of the 1G8279 Pump Group) must be transferred to the 0R4479 Pump Group before installation.

Parking Brake Parts (use only if required)

1 - 4D4508 Seal-O-Ring

2 - 4J0520 Seal-O-Ring

2 - 4J5477 Seal-O-Ring

2 - 9R2495 Seal (CS573, CS583)

2 - 9R6573 Boot Seal Assembly (CS573, CS583)

3 - 6V8398 Seal-O-Ring

2 - 6V9746 Seal-O-Ring

4 - 1028458 Intermediate Disc (CS573, CS583)

8 - 1028459 Disc (CS573, CS583)

1 - 1045352 Seal Brake

1 - 1122380 Brake Kit

Action Required

Parts Stock

Inspect all 1G8279 and 1G9720 Hydraulic Pump Groups in Parts Stock. Locate the pump serial number stamped on the supplier identification tag, and remove all pumps from Parts Stock with any of the pump serial numbers A92-25-XXXXX through A93-25-XXXXX and N92-25-XXXXX through N93-25-XXXXX.

NOTE: If the supplier identification tag has a "Q" stamped to the right side of the serial number, the pump has already been reworked and does not need to be removed from Parts Stock. See Illustration below.

Illustration of Supplier Identification Tag

Affected Product

See attached rework procedure.

Owner Notification

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

Service Claim Allowance

Parts Stock

Submit one claim for all 1G8279 and 1G9720 Hydraulic Pump Groups removed from parts stock.

NOTE: US and Canadian Dealers Only - When submitting a parts stock claim use 99Z00001 in the Product Identification Number Field.

Affected Product

Pump Inspection Only

NOTE: This is a 2.5-hour job.

Pump Update On Units With Less Than 500 SMU

NOTE: This is a 13.0-hour job.

Pump Inspection and Update Before Failure

NOTE: This is a 13.5-hour job.

Pump Inspection and Replacement After Failure

NOTE: This is a 11.5-hour job.

NOTE: If the parking brake needs to be repaired due to a failure, then additional labor hours may be claimed. Up to a maximum of 20 hours of labor may be claimed for the CP533, CS533, CP563 and CS563. Up to a maximum of 34 hours of labor may be claimed for the CS573 and CS583.

NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

Parts Disposition

Dealers in the U.S., Canada, Mexico, and South America

Return all 1G8279 and 1G9720 Hydraulic Pump Groups that are removed from Parts Stock (or removed from a machine) by surface transport and a copy of the claim to:

1G8279 and 1G9720 Hydraulic Pump Groups replaced with a 0R4479 Remanufactured Hydraulic Pump Group should be handled in accordance with your warranty bulletin instructions for remanufactured components.

Dealers in Europe

Return all 1G8279 and 1G9720 Hydraulic Pump Groups that are removed from Parts Stock (or removed from a machine) by surface transport along with a copy of the claim to:

1G8279 and 1G9720 Hydraulic Pump Groups replaced with a 0R4479 Remanufactured Hydraulic Pump Group should be handled in accordance with your warranty bulletin instructions for remanufactured components.

All Other Dealers

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

Rework Procedure

NOTE: Refer to the following Operation and Maintenance Guides:

1. Inspect and record the machine hours per the hour meter.

2. If the machine hour reading is greater than 500 hours, perform the Pump Inspection procedure listed below.

NOTE: If during the pump inspection, the pressure differential in neutral is found to be greater than 200 psi, perform the Pump Update/Replace procedure listed below.

NOTE: If the pressure differential is less than 200 psi, disconnect the tooling and submit a SIMS report with the comment "Pump Is OK".

3. If the machine hour reading is less than 500 hours perform the Pump Update/Replace procedure listed below.

Pump Inspection

NOTE: If a failure of the leveler arm has occurred, the machine may propel forward or reverse with the propel handle in neutral and the parking brake applied. A clear area should be selected fro this test.

NOTE: Use a 4C4892 ORFS Hydraulic Test Kit to conduct the hydraulic pressure tests for this program.

NOTE: Refer to the illustration below showing the drum pump hydraulic port locations:

Location Of Drum Pump Hydraulic Ports

1. Raise the platform or cab.

2. Clean area around the propel cooling valve.

3. Disconnect the following hydraulic hoses. Use steel caps to prevent leaks.

- Two hoses (1) from axle pump to propel cooling valve. Use two 6V9508 Plugs and two 6V9829 Caps.

- Two hoses (2) from drum drive pump to drum drive motor. Use two 6V9511 Plugs and two 6V9832 Caps.

- One hose (3) from propel cooling valve to vibratory cooling valve. Use one 6V9509 Plug and one 6V9830 Cap.

- Disconnect linkage rod between the drum and axle propel pumps.

4. Install two 7500 psi pressure gages to quick disconnects (4) on propel cooling valve. These two quick disconnects are for checking the forward and reverse pressures for the drum drive hydraulic circuit. Having the hydraulic hoses disconnected (from Step 3), will isolate the drum pump from the remainder of the hydraulic circuit.

5. Start the machine and run the engine at high idle. Wait 45 seconds, then observe the two pressure gages for the drum drive pump with the parking brake applied.

NOTE: Calibrated gages should be used. A typical gage reading with the machine in neutral and the engine at high idle would be approximately 400 psi. Due to this, it may be necessary to use gages with a lower pressure range.

6. With the linkage disconnected, parking brake applied, propel handle in neutral position, and engine at high idle, record the "Drum Forward" and "Drum Reverse" pressures. The pressures seen on both the drum forward and the drum reverse should be within 200 psi of each other.

7. If the pressure difference is less than 200 psi, disconnect the tooling and connect the hoses back to their respective ports. Enter a SIMS ticket with the comment "Pump Is OK". No further action is necessary.

8. If the pressure difference is greater than 200 psi, the pump should be removed and either updated or replaced depending upon its condition.

Pump Update/Replace

1. Install a new 1172849 Side Cover and 1084572 Leveler Arm. Refer to the August 15, 1994 Service Magazine article, "Tooling Plate Simplifies Swashplate Neutral Adjustment On Drum Propel Pump". This should be used to supplement procedures for the following disassembly and assembly modules:

NOTE: If upon disassembly of the 1G8279 or 1G9720 Drum Drive Pump the leveler arm is found to be broken and has caused resultant pump damage, the complete pump should be replaced with an 0R4479 Pump. Affected products in Group 1 use a 1G8279 Pump Group. Affected products in Group 2 use a 1G9720 Pump Group. When replacing the existing 1G8279 Pump Group with the 0R4479 Pump Group on affected products in Group 1, the 7R3386 Drive Coupling (a part of the 1G8279 Pump Group) must be transferred to the 0R4479 Pump Group before installation.

2. After installing the pump, the following procedures must be performed:

&- Charge Pressure Relief Valves Adjustments.

&- Propel Pump Synchronization Test.

&- Parking Brake Efficiency Test.

Refer to the Service Manual module on the Propulsion Systems Operation Testing And Adjusting:

NOTE: If the charge pressure relief valves in the vibratory and propel pumps are not properly adjusted, it will lead to component overheating and failure.

NOTE: If the machine does not pass the parking brake efficiency test, repair the parking brake on the drum drive motor (on CP533, CS533, CP563, CS563, CS573 and CS583 Compactors) and rear axle (on CS573 and CS583 Compactors.