PRODUCT SUPPORT PROGRAM FOR REPLACING THE ADJUSTMENT SCREW ON CERTAIN B20 HYDRAULIC HAMMERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE ADJUSTMENT SCREW ON CERTAIN B20 HYDRAULIC HAMMERS

Usage:

TEBE0041-00

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16Aug2013

D-308

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE ADJUSTMENT SCREW ON CERTAIN B20 HYDRAULIC HAMMERS
6333		PS43987

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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 "PS43987" 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 Caterpillar product analyst.

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TERMINATION DATE

31Aug2015

PROBLEM

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The existing adjustment screw on the valve block on certain B20 Hydraulic Hammers allows the hammer to operate at a pressure that is above specification. If the adjustment screw is not replaced, damage to the hammer and the machine may occur.

AFFECTED PRODUCT

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Model	Identification Number
B20	MAX00103-00189, 193-553, 556-570, 574

PARTS NEEDED

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Qty	Part Number	Description
1	3670751	KIT-SEAL (VALVE)
1	4434182	PLUG-PORT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 8% 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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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-10000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

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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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Perform all steps necessary to prepare the machine and the hammer for safely replacing the adjustment screw.

Work must be completed with hammer in the horizontal position. Clean the area around the valve block thoroughly in order to minimize contamination.

Adjustment screw, O-Ring and Backup Ring will be replaced.

Adjustment Screw Location

Refer to Image 1.3.1 and Image 1.3.2.

Image1.3.1

Image1.3.2

Step 1 ? Use a 34mm wrench to loosen the lock nut.
Step 2 ? Use a 12mm hex key to remove the adjustment screw.
Step 3 ? Install O-Ring seal and backup ring onto 443-4182 Plug Port.
Note: O- Ring and Backup Ring are part of 367-0751 Seal Kit.
Refer to Image 1.4.1.

Image1.4.1

Step 4 ? Apply Blue Loctite 242 to the threads of 443-4182 Plug Port.
Step 5 ? Install 443-4182 Plug Port into the valve block of the hammer using 34mm wrench. Refer to Image 1.5.1.

Image1.5.1

Step 6 ? Tighten 443-4182 Plug Port to 150 +/- 10 Nm (110 +/- 7 lb-ft)

Machine Calibration Procedure

Perform all steps necessary to prepare the machine and the hammer for safely calibrating the machine. Refer to the Operation and Maintenance Manual (OMM) for your specific machine OMM for the proper safety procedures.
Before the hammer can be returned to service, the auxiliary lines kit for the machine must be calibrated to ensure the correct flow and pressure is being delivered to the hammer.
Failure to complete this procedure can result in higher owning and operating costs as well as damage to the hammer or the machine.
All testing must be done with the hydraulic oil of the machine at operating temperature ? 50C.

1. Verify the setting of the 361-8824 Auxiliary Circuit Pressure Relief Valve. The valve should be set to 240 - 250 bar. Refer to Image 1.8.1.
a. With the hammer installed, close the return side ball valve on the machine.
b. Install a pressure gauge capable of reading pressure above 250 bar.
c. Activate the auxiliary circuit and record the pressure shown on the gauge.
i. If the relief pressure is above 250 bar, loosen the jam nut and turn the adjustment screw counter-clockwise to reduce the opening pressure for the relief valve. Tighten the jam nut.
ii. If the relief pressure is below 240 - 250 bar, loosen the jam nut and turn the adjustment screw clockwise to increase the opening pressure for the relief valve. Tighten the jam nut.
d. Repeat Step 1c to retest the relieve valve pressure to verify that the valve is set to 240 - 250 bar.
e. Remove the pressure gauge and open the return side ball valve.

Image1.8.1

2. Install a flow meter onto the machine auxiliary circuit. Operate the auxiliary circuit of the machine and record the flow when the flow meter reads 170 Bar. The flow should be 150 Liters per minute (Lpm) at 170 Bar. Flow is adjusted by the 1U-1100 Valve. Refer to Image 1.9.1.
a. If the flow is greater than 150 Lpm at 170 Bar, loosen the jam nut and turn the adjustment screw counter-clockwise to reduce the pilot pressure to the valve spool. Tighten the jam nut.
b. If the flow is less than 150 Lpm at 170 Bar, loosen the jam nut and turn the adjustment screw clockwise to increase the pilot pressure to the valve spool. Tighten the jam nut.
c. Repeat Step 2 in order to retest the flow to the auxiliary circuit.
d. Disconnect the flow meter and reinstall the hammer onto the auxiliary circuit of the machine.