PRODUCT SUPPORT PROGRAM FOR THE INSTALLATION OF AN ACCUMULATOR CIRCUIT FOR THE DRIVE MOTOR WHICH IMPROVES THE FUNCTIONALITY OF THE TWO-SPEED TRAVEL ON THE W345C WHEELED MATERIAL HANDLER Caterpillar

PRODUCT SUPPORT PROGRAM FOR THE INSTALLATION OF AN ACCUMULATOR CIRCUIT FOR THE DRIVE MOTOR WHICH IMPROVES THE FUNCTIONALITY OF THE TWO-SPEED TRAVEL ON THE W345C WHEELED MATERIAL HANDLER [REBE3604]

HYDRAULIC SYSTEM

PRODUCT SUPPORT PROGRAM FOR THE INSTALLATION OF AN ACCUMULATOR CIRCUIT FOR THE DRIVE MOTOR WHICH IMPROVES THE FUNCTIONALITY OF THE TWO-SPEED TRAVEL ON THE W345C WHEELED MATERIAL HANDLER

REBE3604-00

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08Apr2008

U-178

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR THE INSTALLATION OF AN ACCUMULATOR CIRCUIT FOR THE DRIVE MOTOR WHICH IMPROVES THE FUNCTIONALITY OF THE TWO-SPEED TRAVEL ON THE W345C WHEELED MATERIAL HANDLER
5057 5058 5069 5077 5137		PS42659

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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 "PS42659" 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.

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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 AVSpare product analyst.

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TERMINATION DATE

30Apr2010

PROBLEM

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The existing travel motor circuit has experienced premature failures on previous models. Pressure spikes occur in the circuit for the drive motor. Stopping the machine during travel in high gear creates a pressure spike. The addition of the accumulator circuit will help reduce the pressure spikes. The reduction of the pressure spikes, lower cross over relief settings, and lower main relief settings improve the durability and reliability of the drive motor if the two-speed travel function is used.

AFFECTED PRODUCT

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Model	Identification Number
W345C MH FCR	R5K00165-00168

PARTS NEEDED

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Qty	Part Number	Description
12	3D2824	SEAL-O-RING
5	3J1907	SEAL-O-RING
2	3K0360	SEAL-O-RING
1	5I4376	FITTING
2	5P1716	ADAPTER-ORIFICED
8	6V8397	SEAL-O-RING
2	6V8634	CONNECTOR-SEAL
1	6V8781	TEE-FACE SEAL
2	6V9007	ELBOW-90 DEGREE
14	6V9746	SEAL-O RING
2	6V9839	TEE-SWIVEL
3	6V9850	ELBOW-SWIVEL
4	6V9853	ELBOW-90 DEG
2	6Y2349	CONNECTOR-SPL
4	7R0042	ADAPTER
4	8C3324	ELBOW-90 DEGREE
1	8C8988	ELBOW
4	8T4224	WASHER-HARD
4	9X2538	ELBOW-90 DEGREE
4	965866	BOLT
32	1226889	HOSE-HYDRAULIC
157	1226891	HOSE-HYDRAULIC
2	1234750	VALVE-CHECK
2	1242114	COUPLING AS-PERM
2	1242121	COUPLING-PERM
1	1242130	COUPLING-PERM
4	1242153	COUPLING-PERM
1	1242323	COUPLING-PERM
2	2367796	ACCUM GP - SERV
4	2638476	VALVE GP-CHECK-E
2	3028914	BLOCK-JUNCTION
2	3028917	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial 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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For installation instructions of the accumulator circuit, refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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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%
0-10000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 8.0-hour job
The installation requires two people, so the dealership can claim an additional $450 labor.

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PARTS DISPOSITION

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

Rework Procedure

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PART I: Hardware Installation

INSTRUCTIONS:
1. Release hydraulic pressure from hydraulic circuits.

Image1.1.1

Image1.1.2

Production components shown from Lines Gp-Motor ? 271-6508:
(A) Hose as. (199-0943)
(B) Elbow as. (148-8367)
(C) Connector as. (148-8336)
(D) Valve Gp-Control (198-6078)
(E) Motor Gp-Piston (178-0400)
(F) Manifold (185-3211)

New components shown from Kit-Hydraulic ? 318-1489:
(1) Elbow as. (148-8367)
(2) Tee as. (148-8435)
(3) Fitting (5I-4376)
(4) Valve Gp-Check (123-4750)
(5) Hose as. (211-3369)
(6) Hose as. (153-9664)
(7) Elbow as. (148-8371)
(8) Connector as. (148-8318)
(9) Adapter (5P-1716)
(10) Seal-o-ring (3D-2824)
(11) Block-junction (302-8914)
(12) Bracket as. (302-8917)
(13) Elbow as. (148-8347)
(14) Elbow as. (148-8392)
(15) Hose as. (164-5851)
(16) Bolt (096-5866)
(17) Washer (8T-4224)
(18) Connector as. (172-4620)
(19) Accumulator gp. (236-7796)
(20) Tee as. (148-8449)
(21) Valve gp-check (263-8476)
(22) Elbow (9X-2538)
(23) Adapter (7R-0042)
(24) Elbow as. (153-6255)
(25) Hose as. (318-1490)

INSTRUCTIONS (cont?d):
2. After releasing hydraulic pressure from hydraulic circuits, disconnect hose as. (A), remove connector as. (C), and remove elbow as. (B).
3. Install tee as. (2) into side port on valve gp (D).
4. Install elbow as. (1) and fitting (3) onto tee as. (2) as shown in Illustration 2.
5. Install two check valves (4) and two elbow as. (1) onto fitting (3) as shown in Illustration 2.
6. Connect hose as. (5) and hose as. (6) onto the two elbow as. (1) as shown in Illustration 2.

Image1.2.1

Image1.2.2

INSTRUCTIONS (cont?d):
7. Note locations where accumulators (19) are to be mounted relative to valve gp. (D) in Illustration 3.
8. Note location of valve gp. (D) in Illustration 4 relative to where the left accumulator (19) will be mounted.
9. Fasten block (11) onto bracket as. (12) with bolts and washers (17) & (18).
10. Place o-ring (10) onto adapter (9) and install into side port of block (11).
11. Install elbow as. (7) and connector as. (8) onto adapter (9).
12. In order to determine the positioning of bracket as. (12) onto the lower frame assembly, fasten end of hose as. (5) onto elbow as. (7) as shown in Illustration 4.
13. When hose as. (5) is in a good position with no kinks or tight bend radii, mark the resulting location of bracket as. (12) along the circular rim of the lower frame assembly, as shown in Illustration 4, and then weld the bracket as. (12) in place, as shown in Illustration 4.
14. Precharge accumulator to 2500kPa and install connector as. (18) and accumulator gp (19) onto top port of block (11).
15. Install elbow as. (13) and elbow as. (14) onto side port of block (11).
16. Run straight coupling end of hose as. (15) through grommet from the outside of the lower frame as. and fasten onto elbow as. (14) as shown in Illustration 4. (Leave straight end of hose as. (15) loose, so as to position the opposite end later during the installation.)

Image1.3.1

INSTRUCTIONS (cont?d):
17. Note locations where accumulators (19) are to be mounted relative to valve gp. (D) in Illustration 3.
18. Note location of valve gp. (D) in Illustration 5 relative to where the left accumulator (19) will be mounted.
19. Fasten block (11) onto bracket as. (12) with bolts and washers (17) & (18).
20. Place o-ring (10) onto adapter (9) and install into side port of block (11).
21. Install connector as. (8) onto adapter (9).
22. In order to determine the positioning of bracket as. (12) onto the lower frame assembly, fasten end of hose as. (6) onto connector as. (8) as shown in Illustration 5.
23. When hose as. (6) is in a good position with no kinks or tight bend radii, mark the resulting location of bracket as. (12) along the circular rim of the lower frame assembly, as shown in Illustration 5, and then weld the bracket as. (12) in place, as shown in Illustration 5.
24. Precharge accumulator to 2500kPa and install connector as. (18) and accumulator gp (19) onto top port of block (11).
25. Install elbow as. (13) and elbow as. (14) onto side port of block (11).
26. Run straight coupling end of hose as. (15) through grommet from the outside of the lower frame as. and fasten onto elbow as. (14) as shown in Illustration 5. (Leave straight end of hose as. (15) loose, so as to position the opposite end later during the installation.)

Image1.4.1

Image1.4.2

Image1.4.3

Image1.4.4

Image1.4.5

Image1.4.6

INSTRUCTIONS (cont?d):
27. Remove the two manifolds (F) from the drive motors (E), marking each manifold, so as to reinstall later with the correct corresponding drive motor.
28. Drill 1 SAE #6 port into each side of each of the 2 manifolds (F), as shown in Illustrations 8, 9 and 10.
29. Reinstall the two manifolds (F) in the same position they were removed from on the drive motors (E).
30. On left drive motor (E), install two elbow as. (24), one into each of the new ports on manifold (E), as shown in Illustration 7.
31. Install two o-rings (10), one on each of the two adapters (23), and then install each of the two adapters (23) onto the two elbows. (24), as shown in Illustration 7.
32. Install two elbows (22) and two valve gps-check (21) onto the two adapters (23), as shown in Illustration 7.
33. Install one tee as. (20) and one elbow as. (14) onto the valve gp-check (21) that is on the top side of the drive motor (E) and manifold (F), as shown in Illustration 7.
34. Install hose as. (25), so as to join tee as. (20) and valve gp-check (21), as shown in Illustration 7.
35. Fasten 90-degree end of hose as. (15) onto elbow as. (14), as shown in Illustration 7, and then tighten opposite end of the hose as. (15) that is under the lower frame as. (reference Illustration 4 for other end of hose as. (15).

Image1.5.1

Image1.5.2

INSTRUCTIONS (cont?d):
36. On right drive motor (E), install two elbow as. (24), one into each of the new ports on manifold (E), as shown in Illustration 11.
37. Install two o-rings (10), one on each of the two adapters (23), and then install each of the two adapters (23) onto the two elbows. (24), as shown in Illustration 11.
38. Install two elbows (22) and two valve gps-check (21) onto the two adapters (23), as shown in Illustration 11.
39. Install one tee as. (20) and one elbow as. (14) onto the valve gp-check (21) that is on the top side of the drive motor (E) and manifold (F), as shown in Illustration 11.
40. Install hose as. (25), so as to join tee as. (20) and valve gp-check (21), as shown in Illustration 11.
41. Fasten 90-degree end of hose as. (15) onto elbow as. (14), as shown in Illustration 11, and then tighten opposite end of the hose as. (15) that is under the lower frame as. (reference Illustration 5 for other end of hose as. (15).

PART II: Instructions for setting Travel Line Reliefs, Two Speed Signal, Main Relief and Parking Brake Release Valves.
INSTRUCTIONS:

1.Install pressure gauges to rear pump and front pump discharge pressure quick disconnects. Pressure gauge must be rated at 8000psi minimum capacity.

2.Adjust main relief in ?one full turn.? (Make sure main relief pressure is 5200psi or higher)

3.Install Pressure gauges at Test ports on Main Pump.

4. Enter Service Mode in the Monitor by entering Password FFF2 at the prompt.
Scroll down to ?Configurations -> Parameter Setting -> Travel Speed Shift?

a) Scroll down to select the parameter indicated on the chart.
b) Use > button to highlight the corresponding value
c) Use ^ button to increase value to the desired setting and press OK to save
d) Repeat steps 2a through 2c to set the desired values for the indicated parameters.

Image1.7.1

Hit ?OK? to save.

4.Set Monitor to Economy Mode (Light off by Power Mode Switch).

5.Set TRAVEL MODE SWITCH to RABBIT

6.Perform a full Counter Rotate with
Right Track Forward and Left Track Reverse simultaneously.
Note: HOLD ONLY FOR LESS THAN 10 SEC AT A TIME. (If held for more than 10 seconds, the machine will move left)

Image1.8.1

7.Perform a full Counter Rotate with
Left Track Forward and Right Track Reverse simultaneously.
Note: HOLD ONLY FOR LESS THAN 10 SEC AT A TIME. (If held for more than 10 seconds, the machine will move right)

Image1.9.1

8.Install gauge at PK1 port on the two-speed valve (located inside mid-section of carbody). Operate Travel Levers for a Full Counter-rotate. Make sure the monitor is set to High Pressure = 31980 kPa, and Rabbit.
9.Set Pressure Reducing Valve to

Image1.10.1

10.After setting the pressure-reducing valve, adjust restrictor valve (if any) on the 2-speed control valve to full out position. (Only applicable on older style valves)

Image1.11.1

11.Parking Brake ? LH
NOTE: Always make sure machine is in rabbit.
Attach Pressure Gauge to Left Hand Parking Brake Valve (Toward Front of Machine). Operate Levers to Full Counter-rotate.

Image1.12.1

12.After setting, return operating lever to neutral. Adjust restrictor valve to achieve drop in pressure from 800psi to 250psi in 3 +/- .5 sec. NOTE: Always make sure machine is in rabbit.

Image1.13.1

13.Parking Brake ? RH
NOTE: Always make sure machine is in rabbit.
Attach pressure gauge to right hand parking brake valve (Toward rear of machine). Operate Levers to Full Counter-rotate.

Image1.14.1

14.After setting, return operating lever to neutral. Adjust restrictor valve to achieve drop in pressure from 800psi to 250psi in 3 +/- .5 sec. NOTE: Always make sure machine is in rabbit.

Image1.15.1

15. Enter Service Mode in the Monitor by entering Password FFF2 at the prompt.
Scroll down to ?Configurations?
Scroll down to ?Travel Speed Shift?
Change the settings to the following values.