PRODUCT SUPPORT PROGRAM FOR REPLACING THE BUCKET CYLINDER GROUP ON CERTAIN 315D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BUCKET CYLINDER GROUP ON CERTAIN 315D EXCAVATORS [REBE4344]

HYDRAULIC SYSTEM

CYLINDER GP

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BUCKET CYLINDER GROUP ON CERTAIN 315D EXCAVATORS

REBE4344-00

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11May2009

U-190

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE BUCKET CYLINDER GROUP ON CERTAIN 315D EXCAVATORS
5457		PS51664

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51664" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31May2012

PROBLEM

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The piston locknuts in the bucket cylinder may become loose on certain 315D Hydraulic Excavators. The piston locknuts loosening may be caused by insufficient torque.

AFFECTED PRODUCT

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Model

Identification Number

315D LC

CJN00158, 160, 162-170, 172, 176-181, 183, 190, 192, 194-199, 201-203, 205, 207-213, 215-216, 218-219, 221, 227, 229-230, 233, 240-241, 250-252, 256-258, 262-266, 268-276, 278-282, 285-289, 291-292, 294-315, 318-322, 324-334, 336-341, 353-355, 359-360, 362-363, 366-390, 392-403, 405-414, 416-421, 423-424, 426, 428-430, 432-433, 435-449, 451, 455-467, 469, 471, 474-475, 477-487, 490, 493, 495-504, 508, 510-534, 536-546, 548-554, 556-559, 564, 566, 568-572, 574-576, 578, 580, 584-585, 590, 598, 607, 609, 611, 614, 616-617, 620, 623, 627-628, 630-631, 636, 640-641, 646, 648-649, 651-652, 657, 661-662, 666, 668, 672, 674, 681, 683, 688, 693, 695, 700, 702, 704-705, 708, 710-711, 716, 718, 720, 731, 736-738, 756, 783, 786, 803, 806, 831-832, 836-838, 846, 849-851, 869, 872, 874, 876-877, 879, 881-882, 884-887, 891-892, 894, 898, 900, 902, 905, 908, 915, 919-921, 924, 928, 930-931, 934, 937, 987-989, 991, 993-998, 1000, 1002-1003, 1016, 1018, 1020, 1024, 1026, 1028-1033, 1042-1046, 1048-1054, 1058, 1061-1062, 1067-1068, 1072, 1074, 1076-1077, 1082-1083, 1087, 1089, 1097, 1101, 1112, 1138-1140, 1142-1143, 1146-1149, 1161-1163, 1176-1177, 1179-1180, 1182, 1198-1200, 1210-1212, 1229-1230, 1232, 1234, 1236, 1256-1257, 1285, 1365, 1371, 1381

PARTS NEEDED

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Qty	Part Number	Description
1	1P3703	SEAL-RECTANGULAR
2	3B8489	FITTING
2	8T4121	WASHER-HARD
4	8T4185	BOLT
2	8T4196	BOLT
1	8T4223	WASHER-HARD
1	8T4910	BOLT
1	0931292	CLAMP
2	0931434	SEAL-LIP TYPE
2	0960854	SEAL-LIP TYPE
1	1319938	TUBE AS
1	1319942	SUPPORT AS
1	1320002	SUPPORT AS
1	3099974	VALVE GP-RLF PLT (Extension)
1	3228747	CYL GP-0110 1039
1	3350210	VALVE GP-RLF PLT (Retraction)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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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If the cylinder piston lock-nut has loosened, replace with a new bucket cylinder group and adjust the pressure for the line relief valve. 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%
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 14.0-hour job
The set pressure needs to be documented in the claims story.

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PARTS DISPOSITION

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Handle the parts in accordance to your Warranty Bulletin on warranty parts handling.
Scrap all parts completely.

Rework Procedure

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NOTE: Refer to Disassembly and Assembly Manual, KENR5272, for instructions on removing, disassembly, assembly, and installing the cylinder.

NOTE: Refer to Test and Adjusting Manual, RENR9737, for instruction on adjusting the line relief valve.

Use Image 1.3.1. in order to determine the new part numbers for your former cylinder assembly number.

1. Release the hydraulic system pressure.
2. Remove the former bucket cylinder assembly.
3. Install the 096-0854 and 093-1434 Lip Seals and 3B-8489 Fitting to the 322-8747 Cylinder Group. Refer to Image 1.1.1.

Image1.1.1

4. The 131-9938 Tube Assembly and other parts are installed in the new cylinder assembly of Step 3. Refer to Image 1.2.1 and Image 1.2.2. Tighten the 8T-4196 Bolt to a torque of 39 +/- 8 Nm. The final assembly is Image 1.2.3.
5. Install the updated cylinder onto the machine. Start the machine and slowly exercise the bucket circuit to ensure all of the air has been evacuated from the hydraulic oil.
Turn off the machine and check/refill the hydraulic tank to maintain "full" hydraulic service level.

Image1.2.1

Image1.2.2

Image1.2.3

6. Start service mode and input a fixed power shift pressure of 2900 kPa.
7. Make sure the pressure set of the relief valve with Image 1.3.1 and Image 1.3.2.
If the set pressure is out of the requirements, adjust the line relief valve to the pressure shown in Image 1.3.1 and Image 1.3.2.
Refer to Test and Adjusting Manual, "Relief valve (Line) - Test and Adjust".
8. Document the set pressure in the claims story.
9. Clean the hydraulic oil until the cleanliness factor of the hydraulic oil meets ISO 18/15 requirements.