PRODUCT SUPPORT PROGRAM FOR REPLACING HOSE ASSEMBLIES ON CERTAIN 305.5 MINI HYDRAULIC EXCAVATORS Caterpillar


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PRODUCT SUPPORT PROGRAM FOR REPLACING HOSE ASSEMBLIES ON CERTAIN 305.5 MINI HYDRAULIC EXCAVATORS [REBE1433]
HYDRAULIC SYSTEM
LINES GP-AUXILIARY
PRODUCT SUPPORT PROGRAM FOR REPLACING HOSE ASSEMBLIES ON CERTAIN 305.5 MINI HYDRAULIC EXCAVATORS
REBE1433-00

09Jan2007


J012
J021
J022
J080
J440
J490
J540

 
Before/After
 (Limited distribution) 
  

PRODUCT SUPPORT PROGRAM FOR REPLACING HOSE ASSEMBLIES ON CERTAIN 305.5 MINI HYDRAULIC EXCAVATORS

5057
PS42322
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 "PS42322" 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.

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 AVSpare product analyst.


TERMINATION DATE

31Jan2009

PROBLEM

Some of the hose assemblies that are used on certain 305.5 Mini Hydraulic Excavators are prone to leak, particularly around the crimp. New hose assemblies are available that are made from a different bulk material. The new bulk material can operate at higher temperatures and a smaller bend radius is possible.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
305.5 CXZ00126-00250, 256-267

DCK00178, 182, 184-192, 202-216, 225-230, 235-259, 268, 279-286, 290-292, 308-346, 353-364, 371-386
*******Group  2*******
305.5 CXZ00251-00255

DCK00180, 183, 193-201, 217-224, 231-234, 260-267, 269-278, 287-289, 293-307, 347-352, 365-370

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
2 2898677 HOSE AS
2 2915234 HOSE AS
2 2915236 HOSE AS
1 2915243 HOSE AS
1 2915245 HOSE AS
2 2915246 HOSE AS
4 2915253 HOSE AS
1 2930448 HOSE AS
1 2932724 HOSE AS
1 2932725 HOSE AS
1 2932726 HOSE AS
1 2932727 HOSE AS
4 6V8397 SEAL-O-RING
34 6V8398 SEAL-O-RING
*******Group 2*******
1 1071658 TEE-O-RING PORT
1 1569791 CONNECTOR-ORFS
2 2898677 HOSE AS
2 2915234 HOSE AS
2 2915236 HOSE AS
1 2915243 HOSE AS
1 2915245 HOSE AS
2 2915246 HOSE AS
4 2915253 HOSE AS
1 2930448 HOSE AS
1 2932724 HOSE AS
1 2932725 HOSE AS
1 2932726 HOSE AS
1 2932727 HOSE AS
1 2932728 HOSE AS
1 2932729 HOSE AS
1 2932730 HOSE AS
1 2932731 HOSE AS
1 2M9780 SEAL-O-RING
3 3K0360 SEAL-O-RING
1 4I8888 SEAL-RECTANGULAR
4 6V8397 SEAL-O-RING
35 6V8398 SEAL-O-RING
2 6V8722 ELBOW-FACE SEAL
7 7J9108 SEAL-O-RING

ACTION REQUIRED

Group 1 identifies machines without auxiliary lines. Group 2 identifies machines with auxiliary line

The rework procedure lists all of the hose assemblies that have been changed. This program authorizes the dealer to replace ALL of these hose assemblies if ANY of these hose assemblies leak. All of the new hose assemblies are listed in the "Parts Needed" section.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-3000 hrs 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 8.0-hour job for Group 1

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-3000 hrs 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 10.0-hour job for Group 2



PARTS DISPOSITION

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


Rework Procedure


 
On group 1 and group 2 machines, replace original hoses with the replacement hoses listed in Image1.1.1.
Image1.1.1
 
On group 2 machines only, replace original hoses with the replacement hoses listed in Image1.2.1.
Image1.2.1
 
Adapter changes on 260-5272 Lines Gp ? Return. On group 1 and group 2 machines, remove existing Tee As. and Adapter from the 209-3942 Tube As. Install new hardware as illustrated in Image1.3.1,
Image1.3.1
 
1. 107-1658 Tee
2. 4I-8888 Seal
3. 6V-8398 Seal
4. 2M-9780 Seal

On group 1 machines only, reinstalled existing 6V-9831 Cap Assembly to Tee As.
 
Adapter changes on 263-1878 Lines Gp ? Aux. On group 2 machines only, remove original connector for port ?B6? on the main control valve. Replace with the following parts,
1 x 156-9791 Connector
1 x 3K-0360 Seal
1 x 7J-9108 Seal

Replace and installed new elbow assemblies to the auxiliary change over valve as illustrated in Image1.5.1,
Image1.5.1
 
5. 6V-8722 Elbow
6. 3K-0360 Seal
7. 7J-9108 Seal
 
 

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