PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, AND REWORKING IF NEEDED, THE MAIN HYDRAULIC PUMP REGULATOR ON CERTAIN 385C, 385CL, 385CL MH AND 385C FS EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, AND REWORKING IF NEEDED, THE MAIN HYDRAULIC PUMP REGULATOR ON CERTAIN 385C, 385CL, 385CL MH AND 385C FS EXCAVATORS [REBE4586]

HYDRAULIC SYSTEM

PUMP GP

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, AND REWORKING IF NEEDED, THE MAIN HYDRAULIC PUMP REGULATOR ON CERTAIN 385C, 385CL, 385CL MH AND 385C FS EXCAVATORS

REBE4586-00

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13Jan2009

U-14

A-12

D-12

O-11

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, AND REWORKING IF NEEDED, THE MAIN HYDRAULIC PUMP REGULATOR ON CERTAIN 385C, 385CL, 385CL MH AND 385C FS EXCAVATORS
5070		PI31611

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31611" 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 "PI31611" 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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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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COMPLETION DATE	TERMINATION DATE
31Jul2009	31Jan2010

PROBLEM

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The setscrew from the main hydraulic pump regulator needs to be inspected, and reworked if needed, on certain 385C, 385CL, 385CL MH and 385C FS Excavators. The existing adjustment screw on the main hydraulic pump regulators may be loose, resulting in slow acceleration with a feeling of low power.

AFFECTED PRODUCT

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Model	Identification Number
385C	KKK00200-00207
385C FS	EAM00289-00290 MMA00261-00263, 265-266
385C L	EDA00488-00498, 500, 502 KGB00426, 431, 433, 436-442, 444 SBE00335-00358, 360-361, 363, 372, 377-381
385C L MH	WAW00223
385C OEM	MSF00112-00113

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Inspect the main hydraulic pump in order to determine the pumps serial number. If the main hydraulic pump serial number is within range 08417580 to 08910587, refer to the attached Rework Procedure to check for a loose setscrew and rework if needed. If the main hydraulic pump is not within this range, no further action is needed.

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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 0.5-hour job
This is a 0.5-hour job to determine the main hydraulic pump serial number and inspection of the setscrew torque. If a setscrew is loose, an additional 2.0 hours is allowed to complete the test and adjust and calibration process.

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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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR CHECKING AND REWORKING THE MAIN HYDRAULIC PUMP REGULATOR

MODELS INVOLVED - 385C, 385CL, 385CL MH AND 385C FS EXCAVATORS

Dear AVSpare Product Owner:

The setscrew from the main hydraulic pump regulator needs to be inspected on the products listed below. The existing setscrew can be loose, which will lead to slow acceleration and the feeling of low power with the machine. 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 13Jan2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

AVSpare Inc.

Identification #(s)

Attached to 13Jan2009 Service Letter

Rework Procedure

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Perform Steps 1 through 5 of the procedure below in order to determine if the adjustment screw on each main pump regulator valve is fully seated. If you determine that the adjustment screw on each regulator valve is fully seated, no further adjustments are necessary. If you determine that the adjustment screw on one or both of the regulator valves are not fully seated, based on the machine configuration, follow Step 6 of the procedure below in order to improve the performance of the machine.

Image1.1.1

Illustration 1.1.1. shows Front View of Main Hydraulic Pump:
(1) Rear pump regulator
(2) Front pump regulator
(3) Bolts
(4) Cover
(5) Locknut
(6) Adjustment screw

Step 1: Loosen two bolts (3) from cover (4) on rear pump regulator (1) until there is a gap between the cover and the body of the rear pump regulator. Refer to Illustration 1.2.1.

Image1.2.1

Step 2: On the opposite side of rear pump regulator (1), maintain the position of adjustment screw (6) while you loosen locknut (5). Refer to Illustration 1.3.1.

Image1.3.1

Step 3: Determine if adjustment screw (6) is fully seated by turning the adjustment screw clockwise.

NOTE: If the adjustment screw bottoms out when you turn the adjustment screw clockwise, do not exceed a torque of 6.9 Nm (61 lb in). Damage to the valve could result if you exceed this torque.

Step 3a: If the adjustment screw did not turn, no further adjustment of the adjustment screw is necessary. Maintain the position of the adjustment screw while you tighten locknut (5) to a torque of 29 Nm (257 lb in).

Step 3b: If the adjustment screw will turn clockwise, tighten the adjustment screw to a torque of 6.9 Nm (61 lb in). Maintain the position of the adjustment screw while you tighten locknut (5) to a torque of 29 Nm (257 lb in).

Step 4: Tighten two bolts (3) to a torque of 29 Nm (257 lb in).

Step 5: Repeat Steps 1 through 4 in order to check the adjustment screw on front pump regulator (2).

Step 6: If the adjustment screw on either the rear pump regulator or the front pump regulator needed adjustment, perform the procedures found in Step 6.a, 6.b, and 6.c for the pump regulator that needed adjustment. If the adjustment screw on both the rear pump regulator and the front pump regulator did not turn, no further adjustments are necessary.

Step 6a: Use Testing and Adjusting, RENR7365-02, ?Margin Pressure - Test and Adjust? procedure to adjust the margin pressure on the front pump and on the rear pump.

Step 6b: If your machine is set "HPC ON" (Duplicate Load Signal), use Testing and Adjusting,
RENR7365-02, "Relief Valve (Signal) - Test and Adjust" procedure to adjust the low pressure circuit and the high pressure circuit.

Step 6c: If your machine is equipped with a AUX HP tool circuit, use Testing and Adjusting, RENR5405, "Auxiliary Valve Spool - Calibrate" procedure to perform a AUX HP tool flow calibration.