PRODUCT SUPPORT PROGRAM FOR REWORKING THE 286-6528 AND 269-9928 MAIN PUMP SNUBBER LINES ON CERTAIN 330D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 286-6528 AND 269-9928 MAIN PUMP SNUBBER LINES ON CERTAIN 330D EXCAVATORS [REBE1484]

HYDRAULIC SYSTEM

LINES GP-PUMP

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 286-6528 AND 269-9928 MAIN PUMP SNUBBER LINES ON CERTAIN 330D EXCAVATORS

REBE1484-01

Show/hide table

05Dec2006

(Revised 16Jan2007)

U-771

A-734

Show/hide table

*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 286-6528 AND 269-9928 MAIN PUMP SNUBBER LINES ON CERTAIN 330D EXCAVATORS
5057		PS42300

Show/hide table

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 "PS42300" 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.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the December 5, 2006 Service Letter. Changes have been made to add Group 2.

Show/hide table

TERMINATION DATE

31Dec2007

PROBLEM

Show/hide table

The existing snubber lines may not perform as desired/expected on certain 330D Excavators. A new lines routing is available that reduces bending stress on the couplings and significantly extends component life.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
330D	NBD00153-00159, 173-174, 177-196, 200, 202-206, 210-223, 226-246, 248, 250, 253-279, 293, 299-308, 315-324, 331-332, 349-352, 354-356, 361-362, 368-369, 371-372, 376, 388-389, 394, 401-404, 414, 447, 450, 507-508, 512, 518, 522, 525, 528-529
330D FM	L2K00215-00219
330D FM BUTT N	E4K00236-00237
330D FM HEEL	H3K00225-00234
330D L	HAS00251-00324 MWP00181-00949
330D MH	LEM00186-00189

Show/hide table

*****Group 2*****
330D	B6H00100-00508 JLP00101-00153, 156-190

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
1	0857356	FITTING-SPECIAL
1	2866528	HOSE AS
1	2967079	SUPPORT AS
1	2967081	SUPPORT AS
1	2S4078	SEAL-O-RING
2	3J1907	SEAL-O-RING
2	5K9090	SEAL-O RING
1	6V9875	CONNECTOR-SPL
1	8T4121	WASHER-HARD
1	8T4195	BOLT
*****Group 2*****
1	0857356	FITTING-SPECIAL
1	1114837	CLIP
1	2827050	HOSE AS
1	2866526	SUPPORT AS
2	2866528	HOSE AS
1	2967079	SUPPORT AS
1	2967081	SUPPORT AS
1	2S4078	SEAL-O-RING
2	3J1907	SEAL-O-RING
2	5K9090	SEAL-O RING
1	5P7462	CLIP
1	5P7463	CLIP
1	6V0683	GROMMET
1	6V9875	CONNECTOR-SPL
3	8T4121	WASHER-HARD
3	8T4195	BOLT

ACTION REQUIRED

Show/hide table

Rework the main pump snubber lines group per the attached Rework Procedure. Refer to ?Operation And Maintenance Manual? Media Number SEBU8046 and ?Disassembly and Assembly Manual? Media Number RENR8648.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 1
Up to $200 allowed for travel time and mileage.

Show/hide table

Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 4.0-hour job for Group 2
Up to $200 allowed for travel time and mileage.

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

REMOVE:

1) Remove the 286-6528 Branch Line from the 148-8391 Elbow, driven pump only. Remove the branch line from the rubber clamps and remove from machine.
2) Prepare to remove the 282-7048 Bracket. Leave the 5P-7462 and 5P-7463 Clips, and the 6V-0683 Grommet on the 282-7050 Pilot Line.
3) Remove the 282-7048 Bracket from the machine.
4) On the 255-1943 bracket, loosen the harness mounting bolt and cut the plastic clip 111-4837 (not shown). Remove the 255-1943 bracket from the machine
5) Remove the 148-8391 Elbow from the pump.

Image1.1.1

INSTALL:

6) Install 296-7079 Bracket reusing the 2x 8T-4223 Washers and 2x 8T-4139 (M12) Bolts. Tighten to a torque of 100 ? 20 Nm.
7) Install 296-7081 Bracket reusing 2x 8T-4121 Washers and 2x 8T-4195 (M10) Bolts. Tighten to a torque of 55 ? 10 Nm.
8) Assemble 5P-7462 and 5P-7463 Clips to 296-7081 Bracket using a new 8T-4121 Washer and a new 8T-4195 (M10) Bolt. Tighten to a torque of 55 ? 10 Nm.

Image1.2.1

9) Secure the wiring harness to the new 269-7079 bracket using a 111-4837 plastic clip, 8T-4137 (M10) bolt & 8T-4121 washer. Torque to 30 ? 5 Nm.

Image1.3.1

10) Remove 6V-3965 Pressure Tap Nipple after removing the dust cap. Install 085-7356 Elbow with 3J-1907 Seal. Orient as shown and tighten to a torque of 48 ? 5 Nm. Reinstall 6V-3965 Pressure Tap Nipple with a new 3J-1907 Seal in the 085-7356 Elbow and tighten to a torque of 48 ? 5 Nm. Reinstall the dust cap on the pressure tap nipple.
11) Install 6V-9875 Connector using a new 2S-4078 Seal into the pump port and tighten to a torque of 350 ? 35 Nm.

Image1.4.1

12) Remove plug from the end of the original branch line, replace the seal with a new 5K-9090 O-Ring.
13) Install a new 5K-9090 O-Ring to the 6V-9875 Connector.
14) Assemble the new 286-6528 Branch Line at 25? from vertical as shown. While maintaining the 25? offset, tighten the 286-6528 Branch Line Fitting to a torque of 190 ?20 Nm.

Image1.5.1

15) Loosely assemble the straight end of the 286-6528 Hose in the rubber clamp.

Image1.6.1

16) Adjust the 286-6528 Branch Line so there is 150mm extending past the rubber clamp.
17) While maintaining the 150mm dimension, tighten the bolts on the rubber clamp to a torque of 55 ? 10 Nm.
18) At this point the installation is complete.

Image1.7.1

Group Number 2

REMOVE:

1) Remove the 269-9928 branch line from the 148-8391 elbow at both drive and driven side pumps. Remove the branch lines from the rubber clamps in all 4 locations.
2) On the 255-1943 bracket, loosen the harness mounting bolt and cut the plastic clip 111-4837. Remove the 255-1943 bracket from the machine.
3) Remove the 269-9934 bracket for the drive side pump branch line from the machine.
4) Remove 148-8391 elbow from the pump driven side only.
5) At approximately B6H00255 a longer pilot hose (282-7050) was installed (850mm long) at the factory. If the machine is equipped with the shorter pilot hose (shown) 275-1760 (400mm long), remove the hose and replace with the longer 282-7050 hose and torque hose ends to 55+/-5 Nm. Otherwise no action is required.

Image2.1.1

INSTALL:

6) Install 296-7079 bracket reusing the 2x 8T-4223 washers and 2x 8T-4139 (M12) bolts. Torque to 100 ? 20 Nm.
7) Install 296-7081 bracket using new 2x 8T-4121 washers and 2x 8T-4195 (M10) bolts. Torque to 55 ? 10 Nm.
8) Secure the 282-7050 pilot hose with 5P-7462 and 5P-7463 clips and 6V-0683 grommet to 296-7081 bracket using a new 8T-4121 washer and a new 8T-4195 (M10) bolt. Torque to 55 ? 10 Nm.

Image2.2.1

9) Remove the 275-1622 bracket from the machine and install the 286-6526 bracket using the same hardware. Torque to 55 ? 10 Nm.

Image2.3.1

10) Secure the wiring harness to the new 269-7079 bracket using a 111-4837 plastic clip, 8T-4137 (M10) bolt & 8T-4121 washer. Torque to 30 ? 5 Nm.

Image2.4.1

11) Driven Side Only -Remove 6V-3965 pressure tap nipple after removing the dust cap. Install 085-7356 elbow with 3J-1907 seal. Orient as shown and toque to 48 ? 5 Nm. Reinstall 6V-3965 pressure tap nipple with a new 3J-1907 seal in the 085-7356 elbow and torque to 48 ? 5 Nm. Reinstall the dust cap on the pressure tap nipple.
12) Driven Side Only - Install 6V-9875 connector using a new 2S-4078 seal into the pump port and torque to 350 ? 35 Nm.

Image2.5.1

13) Remove plug from the end of the original branch line, replace the seal with a new 5K-9090 o-ring. Install plug on the new 286-6528 branch line. Torque the plug to 190?20 Nm.
14) Install a new 5K-9090 o-ring to the 6V-9875 connector.
15) Next, assemble the new 286-6528 branch line at 25? from vertical as shown. While maintaining the 25? offset torque the 286-6528 branch line fitting to 190?20 Nm.

Image2.6.1

16) Loosely assemble the straight end of the 286-6528 hose in the rubber clamp. Adjust the 286-6528 branch line so there is 150mm extending past the rubber clamp.While maintaining the 150mm dimension, torque the bolts on the rubber clamp to 55?10 Nm.

Image2.7.1

17) Remove plug from the end of the original 269-9928 branch hose, replace the seal with a new 5K-9090 o-ring. Install plug on the new 286-6528 branch line. Torque the plug to 190?20 Nm.
18) Clamp the new 286-6528 branch lines so there is 150mm extending past the rubber clamp to the end of the plug. Torque the bolts on the rubber clamp to 55?10 Nm.
19) At this point the installation is complete.