PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING CERTAIN HYDRAULIC HOSE ASSEMBLIES ON CERTAIN PM-200 COLD PLANERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING CERTAIN HYDRAULIC HOSE ASSEMBLIES ON CERTAIN PM-200 COLD PLANERS

Usage:

TEBE4575-00

Show/hide table

28Apr2016

D-183

Show/hide table

Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING CERTAIN HYDRAULIC HOSE ASSEMBLIES ON CERTAIN PM-200 COLD PLANERS
3154		PI11066

Show/hide table

NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI11066" 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 "PI11066" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

PROBLEM

Show/hide table

The XT6-12 hose assemblies need to be inspected and may need to be replaced on the Affected Product. These hose assemblies, if manufactured from ?? XT6ES (161-1835) or ToughGuard (238-8346) bulk hose manufactured from 27-Jul-15 through 31-Oct-15 may fail due to a manufacturing defect. If one of these hose assemblies fail it may develop a pin hole leak or blister of oil within the hose which may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
PM-200	P1C00640-00642

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
3	1P3702	SEAL-RECTANGULAR (AS NEEDED)
29	6V9746	SEAL-O-RING-ORFS (AS NEEDED)
1	1873204	HOSE AS. (IF REQUIRED)
1	2138823	HOSE AS. (IF REQUIRED)
1	2695796	HOSE AS (IF REQUIRED)
1	2695799	HOSE AS. (IF REQUIRED)
1	2695800	HOSE AS. (IF REQUIRED)
1	2695801	HOSE AS. (IF REQUIRED)
1	2695807	HOSE AS. (IF REQUIRED)
1	2695809	HOSE AS. (IF REQUIRED)
1	2695810	HOSE AS. (IF REQUIRED)
1	2700415	HOSE AS. (IF REQUIRED)
1	2700416	HOSE AS. (IF REQUIRED)
1	2712004	HOSE AS. (IF REQUIRED)
1	2712006	HOSE AS. (IF REQUIRED)
1	2712007	HOSE AS. (IF REQUIRED)
1	2729975	HOSE AS. (IF REQUIRED)
1	2741208	HOSE AS. (IF REQUIRED)
1	HYD_OIL	HYD OIL (UP TO 19L (20QT) - SEE OMM))
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

Show/hide table

Refer to the service manual if/as necessary and see the attached rework procedures.

The impacted hose has a cure date range from 27-Jul-15-6 through 31-Oct-15-6. The cure date is ink jet printed in white ink (Image 1) and can be found on the black portion of the hose surface (not in the hose layline). Prior to removal of the assembly, locate the cure date on the hose. If the date is from 27-Jul-15-6 through 31-Oct-15-6, or if the cure date cannot be found on the hose, remove and replace the assembly following the rework procedure. The cure date of the hose is NOT located on the white tag (Image 2) found on the hose assembly.

Show/hide table

Image1

Image2

OWNER NOTIFICATION

Show/hide table

Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

Show/hide table

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

Show/hide table

NOTE: This is a 2.0-hour job
This is a 2-hour job to inspect the hoses. Up to 1.5 hours per hose will be allowed for hose replacement. If hose replacement(s) are necessary, 1 hour is allowed to check out the machine after completion of all needed hose replacements.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Show/hide table

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING CERTAIN HYDRAULIC HOSE ASSEMBLIES ON CERTAIN PM-200 COLD PLANERS.

MODELS INVOLVED - PM-200

Dear Cat Product Owner:

The XT6-12 hose assemblies need to be inspected and may need to be replaced on the Affected Product. These hose assemblies, if manufactured from ?? XT6ES (161-1835) or ToughGuard (238-8346) bulk hose manufactured from 27-Jul-15 through 31-Oct-15 may fail due to a manufacturing defect. If one of these hose assemblies fail it may develop a pin hole leak or blister of oil within the hose which may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 28Apr2016 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 28Apr2016 Service Letter

Rework Procedure

Show/hide table

Introduction

This rework procedure on will provide the necessary steps to identify and check certain hydraulic hoses on certain PM-200 Cold Planers. This procedure provides the criterion for replacing the hoses. This procedure provides instructions for replacing the hoses. This procedure provides a check out procedure after the completion of the rework.

Read the entire procedure. Understand the information before you perform any procedures. Understand the information before you order any parts or perform any work.

Safety Section

Image1.2.1

Image1.2.2

Image1.2.3

Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the controls. Attach the warning tag before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Cat dealer.

Trapped Pressure

Pressure can be trapped in a hydraulic system. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or fittings. High-pressure oil that is released can cause a hose to whip. High-pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and possible death.

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the machine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure.

Image1.4.1

Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken in order to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the equipment. Prepare to collect the fluid with suitable containers before opening any compartment or disassembling any component that contains fluids.

Refer to Special Publication, NENG2500, "Cat dealer Service Tool Catalog" for the following items:

Tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids

Tools that are suitable for containing fluids and equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.

Image1.5.1

Machine Preparation

Empty the water tank.
Drive the machine to a smooth, horizontal surface.
Move propulsion lever (7) to the NEUTRAL position.
Move parking brake switch (3) to the ON position.
Make sure rotor switch (8) is in the OFF position.
Make sure conveyor switch (10) is in the OFF position.
Make sure water spray switches (5, 6, and 9) are in the OFF position.
If necessary, move engine control switch (4) to the MANUAL position.
Lift the rear of the machine to service height.
Install the rear service locks.
Place high density plastic protective plates on the floor under the rotor.
Lower the front until the rotor is resting on the plates.
Switch off the machine with the key switch.
Switch off the main battery ground switch.
Attach a ?Do not Operate? warning tag or similar warning tag to the start switch or to the controls.

Rework Procedure

Identify and locate the respective hoses using Table 1 and attached illustrations.

Image1.7.1

Check the date code printed on each hose case (Image1.8.1) The date code is printed directly on the hose in light white lettering at regular intervals along the length of the bulk hose. The date code will be found on the black portion of the hose, not on the lay line area. Use a flashlight to help illuminate the code.

Image1.8.1

Note: Do not use the date code from the tag on the assembled hose (Image1.9.1) as these two dates are not necessarily aligned.

Image1.9.1

If the date code is between 27-Jul-15-6 through 31-Oct-15-6, replace the hose.

If the date code cannot be located on shorter hoses, then replace the hose.

If outside the date range, no further action is needed for the hose.

Replacing the Hose

Remove guards, clamps and cable straps necessary to remove the hose assembly.
Remove the hose assembly.
Replace the o-ring seals.
Install the replacement hose in reverse order of removal.
Reinstall guards, clamps and cable straps to secure the hose assembly.
If possible, replace all hoses requiring replacement at the same time.

Post Repair

Top off hydraulic tank oil level.
Note: The expected and allowable oil volume per hose is provided in Table 1. Refer to PM-200 OMM for applicable oil type.
Clean machine of any spilled oil that occurred during the hose replacements.
Bring machine to operating temperature.
Cycle affected circuits.
Monitor the hydraulic tank level - top off the tank is required.
Check for proper function.
Park the machine and turn off the engine.
Check for leaks at the fitting connections.
Repair any leaks.
Return machine to service.

Hose Identification Illustrations