Product Improvement Program For Replacing Stems In The Machine Control Valve On Certain 318C, 320C, 320D, 320D RR, 321C CR, 325D, And 330D Excavators Caterpillar

Product Improvement Program For Replacing Stems In The Machine Control Valve On Certain 318C, 320C, 320D, 320D RR, 321C CR, 325D, And 330D Excavators [REBE1658]

HYDRAULIC SYSTEM

VALVE GP-CONTROL

Product Improvement Program For Replacing Stems In The Machine Control Valve On Certain 318C, 320C, 320D, 320D RR, 321C CR, 325D, And 330D Excavators

REBE1658-00

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13Mar2007

U-93

A-78

D-78

O-86

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING STEMS IN THE MACHINE CONTROL VALVE ON CERTAIN 318C, 320C, 320D, 320D RR, 321C CR, 325D, AND 330D EXCAVATORS
5051		PI10583

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10583" 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 "PI10583" 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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PROBLEM

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The machine control valve may have been assembled with oversized control valve stems on certain 318C, 320C, 320D, 320D RR, 321C CR, 325D, and 330D Excavators. Current stems may lead to implement (boom, bucket, stick, swing or travel) circuit malfunction, which may cause personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
320C	PAB07640, 7643, 7645, 7647-7648, 7650-7651, 7653-7657, 7659-7661, 7663, 7668, 7670, 7672-7674, 7678, 7681-7682, 7684-7686, 7689-7693, 7695-7715, 7717-7718, 7722, 7726, 7730, 7737, 7739, 7745-7746, 7748-7749, 7752-7753, 7755-7758, 7764, 7771
320D	CXY00228 DHK00726-00728, 731-732, 739, 753, 809-810, 816, 821 JGZ00617, 825-831, 834-842, 851-855, 859-860, 862-864, 875-881, 886-922, 924-926, 933-938, 940-942, 944-946, 951-962, 964-997, 999-1003, 1005-1024, 1031-1039, 1042-1044, 1051-1081, 1083-1084, 1086, 1088-1092, 1094-1095, 1099, 1101, 1103-1106, 1111-1112
320D L	MDE00201, 218, 249-266, 273-275, 277-282, 285-289
320D LRR	FXK00215, 217
321C LCR	KCR00272, 275, 281 MCF01131
325D	SCR00511-00512, 514, 517, 525
330D	EAH00266-00271, 273-274 FFK00156-00159 MEY00231, 245, 249 NBD00532, 535, 537, 541, 547, 554

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*****Group 2*****
318C	GPA00501-00502 MDY00782, 784-786

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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1. Refer to the attached Rework Procedure and replace incorrect stem.

2. Please refer to Image 1 for newly released part numbers by model and location to exchange affected stems.

3. The affected locations of stems are identified by machine serial number in Image 2 to Image 14. The incorrect stem is shown with a circle in this list.

4. Cat Dealers are to E-mail Takuya Aoyama within the Excavator Product Support Group, using the following E-mail address: takuya_aoyama@scm.co.jp. Provide Takuya Aoyama the following information:
A) Dealer contact person for the address shipping label.
B) Their desired ship to address.
C) Telephone number with country code.
D) Machine serial number.
E) Main control valve serial number.
SCM's logistics provider will ship direct to Cat Dealer individual KITs of replacement stems specific to the machine and main control valve serial numbers E-mailed by the Cat Dealer. On the outside packaging of each KIT will state the applicable machine and main control valve serial number for easy dealer identification.

5. Included in the KIT will be a SCM "no charge" Proforma Invoice for normal customs and importation requirements. Applicable landing costs of freight, duty, and taxes will be paid by dealer and reimbursed through normal warranty procedure using this Service Letter.

6. Image 15 shows the needed tool list.

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Image1

Image2

Image3

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Image5

Image6

Image7

Image8

Image9

Image10

Image11

Image12

Image13

Image14

Image15

OWNER NOTIFIAVSION

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

SERVICE CLAIM ALLOWANCES

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 4.0-hour job for Group 1
AVSpare covers 100% follwing expense when dealer claims. 1.Travel time and mileage. 2.Hydraulic oils and disposal of oil. 3.All landed costs of taxes, duty, and freight.

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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 4.0-hour job for Group 2
AVSpare covers 100% follwing expense when dealer claims. 1.Travel time and mileage. 2.Hydraulic oils and disposal of oil. 3.All landed costs of taxes, duty, and freight.

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PARTS DISPOSITION

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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 NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - Product Improvement Program For Replacing Stems In The Machine Control Valve

MODELS INVOLVED - 318C, 320C, 320D, 320D RR, 321C CR, 325D, And 330D Excavators

Dear AVSpare Product Owner:

The correct stems need to be installed in the machine control valve on the products listed below. Current stems may lead to implement (boom, bucket, stick, swing or travel) circuit malfunction, with the potential for serious injury or death. You will not be charged for the service performed.

Contact your local AVSpare 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 13Mar2007 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

AVSpare Inc.

Identification #(s)

Attached to 13Mar2007 Service Letter

Rework Procedure

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1. Locate the machine at rework area and rest the front linkage on the ground.

2. Turn the engine key off and leave the hydraulic lock lever in the operational position. Release the residual hydraulic pressure of pilot lines by moving the implement control lever. Place the hydraulic lock lever in the locked position.

3. Loosen the oil supply plug on the top of the hydraulic tank to relieve the tank pressure.
Use the 9U-6639 Ratchet and 194-3565 Socket.

Image1.3.1

4. Loosen four bolts of the upper cover and remove cover.
Use the 9U-6639 Ratchet and 6V-9113 Socket.

Image1.4.1

5. Check the S/N of control valve with the rework list to confirm the correct stems are available.

Image1.5.1

6. Remove the cover under the control valve.
Use the 9U-6639 Ratchet and 6V-9113 Socket.

Image1.6.1

7. Loosen the connector of the pilot hose in order to adjust the hose angle. Loosen the mounting bolt for the 158-8159 Control Valve Housing.
Use 214-7218 Wrench.

Image1.7.1

8. Pull out the stem that needs replaced. Refer to rework machine list in the Action Required section.
Note: Only for ATT stem, loosen the plug of 6E-2274 Cover to relief trapped pressure in order to pull out and insert the stem smoothly.
Caution: Make sure you have safety glasses and pull slowly the stems because the oil may squirt. Pull straight up. Avoid cocking the stem on the way in and out as it may cause damage to stem and/or bore of control valve. Once damaged, the new stem might not be able to be put in or friction may increase during machine operation.
Use the 9U-6639 Ratchet and 6V-9111 Socket.

Image1.8.1

9. Check the part number of previous stem and new stem to prevent mis-assembling.

10. Place the stem in the bore opening. Carefully insert the stem while turning slightly.
Note: Only for ATT stem, loosen the plug of 6E-2274 Cover to relief trapped pressure in order to pull out and insert the stem smoothly.

Image1.10.1

11. Reinstall the 158-8159 Housing and tighten the mounting bolts to a torque of 49 +/- 5 Nm.
Caution: The O-ring seal should be in place without binding when assembling housing.
Use the 214-7218 Wrench and 214-7349 Torque Wrench.

Image1.11.1

12. Purge the air from the system. Loosen the connection of pilot hose and start the engine. Operate the engine at low idle in order to bleed air from the pilot hoses at the replaced stems. After bleeding, tighten the connector to a torque of 40 +/- 4 Nm.
Use the 6V-9102 Wrench and 214-7349 Torque Wrench with No.22 Open-End Wrench.

Image1.12.1

13. Reconnect all pilot hoses and tighten to a torque of 40 +/- 4 Nm.
Use the 6V-9102 Wrench and 214-7349 Torque Wrench with No.22 Open-End Wrench.

14. Double check the tightening torque of each bolt after all the planned stems are replaced. Tighten an oil supply plug on the top of the hydraulic tank.
Use the 9U-6639 Ratchet and 194-3565 Socket.

15. Operate each function at engine low idle and confirm lever pattern is correct. Adjust dial speed to high idle and warm up the machine until hydraulic oil temperature becomes 50 Deg.C. Confirm that oil is not leaking and implements function as intended.

16. Keep hydraulic oil temperature at 50 Deg.C to 60 Deg.C with high idle engine speed. And check hydraulic drifts on following items based on RENR6639 for 318C, RENR3817 for 320C, RENR7105 for 321C, RENR7295 for 320D, RENR7385 for 325D, and RENR9585 for 330D "Testing and Adjusting".
1) Cylinder Drift-Check(Empty Bucket) for each cylinder.
2) Machine Drift-Check on a slope.
3) Swing Drift-Check on a slope.

17. Stop engine.

18. Obtain a hydraulic oil sample from the main S.O.S port.
Reference: Refer to Operation and Maintenance Manual, "Sampling Interval and Location of Sampling Valve" for the correct location.

If the S.O.S sample exceeds ISO 18/15, flush the hydraulic system.
Reference: Refer to Contamination Control Guidelines, SEBF8436, "Hydraulic System Flushing Procedure".

Using 170-8500 Particle Analyzer.

19. Wipe spilled oil and reinstall the under cover.

20. Assemble the upper cover and tighten to a torque of 50 +/- 10 Nm.
Use the 9U-6639 Ratchet and 6V-9113 Socket.

21. Cut the old stems into pieces and discard.