PRODUCT IMPROVEMENT PROGRAM FOR REPLACING MACHINE SOFTWARE AND INSPECTING STEERING PUMP ACTUATORS ON CERTAIN PL83 PIPELAYERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING MACHINE SOFTWARE AND INSPECTING STEERING PUMP ACTUATORS ON CERTAIN PL83 PIPELAYERS

Usage:

TEBE7528-02

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30Mar2018

(Revised 06Jun2018)

U-181

A-134

D-161

O-165

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING MACHINE SOFTWARE AND INSPECTING STEERING PUMP ACTUATORS ON CERTAIN PL83 PIPELAYERS
7620 4800 4808 7610 5078 5070		PI11140

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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 "PI11140" 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 "PI11140" 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:	This Revised Service Letter replaces the 30Mar2018 (Revised 23Apr2018) Service Letter. Changes have been made to the Problem, Parts Needed, Action Required, Service Claim Allowances, and Rework Procedure.

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PROBLEM

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Under certain operating conditions, forces acting on the steering pump actuator spring collars can become too high, resulting in a broken spring collar. A broken spring collar could potentially prevent the steering pump actuator from returning to a neutral position. If a steering pump actuator is prevented from returning to a neutral position, unintended machine movement can occur. This may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

New Powertrain software has been developed to reduce steering control current and reduce maximum motor speed by approximately 10 percent in order to lower forces exerted on spring collars inside the steering pump actuator. This new Powertrain software needs to be installed on certain PL83 Pipelayers with the KSD serial number prefix.

In addition, an inspection needs be performed on the steering pump actuator spring collars to check for cracks. Then the steering pump actuator cartridge needs to be replaced with a 5604509/">560-4509 steering pump actuator cartridge.

AFFECTED PRODUCT

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Model	Identification Number
PL83	KSD00120-00304

PARTS NEEDED

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Qty	Part Number	Description
4	1P3704	SEAL-RECTANGULAR
1	2K8257	SEAL-O RING
1	2M9780	SEAL-O-RING-STOR
1	3D2824	SEAL-O-RING-STOR
1	3J1907	SEAL-O-RING-STOR
1	4J0522	SEAL-O-RING
8	5A3604	BOLT-HEX SOCKET
1	5K9090	SEAL-O-RING-ORFS
1	6J2680	SEAL-O-RING
3	6V9746	SEAL-O-RING-ORFS
1	7J9108	SEAL-O-RING-ORFS
2	7M8485	SEAL-O-RING-STOR
2	8C3089	SEAL-O-RING
1	1616149	SEAL-O-RING
1	2808867	GASKET
1	3511768	SEAL-O-RING
1	5604509	CARTRIDGE GP-B
1	5621900	SFWR GP-A5000
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

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Refer to the attached Rework Procedure.

Note: No additional rework is required if the machine has already completed this program.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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Caterpillar		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 20.0-hour job
Note: The 20.0 hours listed above are to remove the steering pump, inspect spring collars, re-install the steering pump, and flash software. An additional 10.0 hours of labor will allowed to remove the existing actuator cartridge and install a new actuator cartridge. If the existing actuator cartridge can not be removed and a new actuator cartridge installed a local Dealership, a maximum of $2,000 U.S. Dollars will be allowed for labor to have the new 5604509/">560-4509 actuator cartridge installed and tested at a qualified hydraulics repair shop. Include outside expenses at cost. Retain a copy of all invoices for outside expenses in the machine folder for audit purposes. Note: Make sure CPI Feedback requested in Step 13 has been submitted in SIMSi before filing a claim. Note: It is IMPORTANT to document the part number of the steering pump actuator cartridge that was installed during the rework.

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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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING MACHINE SOFTWARE AND INSPECTING STEERING PUMP ACTUATORS ON CERTAIN PL83 PIPELAYERS

MODELS INVOLVED - PL83 Pipelayer

Dear Cat Product Owner:

Under certain operating conditions, forces acting on the steering pump actuator spring collars can become too high, resulting in a broken spring collar. A broken spring collar could potentially prevent the steering pump actuator from returning to a neutral position. If a steering pump actuator is prevented from returning to a neutral position, unintended machine movement can occur. This may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

New Powertrain software has been developed to reduce steering control current and reduce maximum motor speed by approximately 10 percent in order to lower forces exerted on spring collars inside the steering pump actuator. This new Powertrain software needs to be installed on the products listed below.

In addition, an inspection needs to be performed on the steering pump actuator spring collars to check for cracks.

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 CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 30Mar2018 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 30Mar2018 Service Letter

Rework Procedure

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1) Read and understand the Operation and Maintenance Manual for safety information and safe working practices before starting this Rework Procedure.

2) Obtain 562-1900 Powertrain software or latest version of Powertrain software from SIS Web. The new software is a direct replacement for the previous software group on the affected product.

3) Download Product Status Reports (PSRs) (with Histograms) in pdf format. Name the file using the following convention: "Machine serial number and Service Letter Number and Before Powertrain Installation". This file will be utilized in a future step.

4) Remove 355-2401 steering pump from machine so the steering pump actuator spring collars can be inspected.

Image1.1.1

5) Remove end caps from steering pump actuator (See Image 1.2.1 and Image 1.2.2)
** Adjustment End Cap: Remove (4) bolts on end cap. Then loosen locknut while holding adjustment screw. DO NOT turn adjustment screw. Next, continue holding adjustment screw and thread end cap off adjustment screw. DO NOT turn adjustment screw.
** Non Adjustment End Cap: Remove (4) bolts on end cap. Then remove end cap.

Image1.2.1

Image1.2.2

6A) Visually inspect actuator spring collars for cracks. Image 1.3.1 shows the location of both spring collars. Take pictures of both actuator spring collars and name the files using the following convention:
** "Serial Number - Service Letter Number - Adjustment Side Spring Collar"
** "Serial Number - Service Letter Number - Non Adjustment Side Spring Collar".

Note: The pictures will be used in a future step of this Rework Procedure.

Image1.3.1

6B) Image 1.4.1 shows an actuator spring collar with no cracks.

Image1.4.1

6C) Image 1.5.1 shows an actuator spring collar with crack initiation.

Image1.5.1

6D) Image 1.6.1 shows an actuator spring collar with crack initiation and significant crack propagation.

Image1.6.1

7) If no cracks are found during the inspection or cracks are found during the inspection, replace existing steering pump actuator cartridge, 183-8417, with a 5604509/">560-4509 actuator cartridge. Go to STEERING PUMP ACTUATOR CARTRIDGE REPLACEMENT section in this Rework Procedure. After the steering pump actuator cartridge is replaced and bench tested, Go to Step 8.

8) Re-install steering pump in machine.

Image1.8.1

9) Reattach hoses using new seals. Image 1.10.1 shows the location of the following seals: (A) 2K-8257, (B) 351-1768, (C)7M-8485, (D) 6V-9746, (E) 1P-3704, (F) 6J-2680, (G) 3D-2824, (J) 4J-0522, (K)7J-9108, (L) 2M-9780, (M) 5K-9090, (N) 280-8867.

Image1.9.1

10) The steering pump will need to be tested and adjusted on the machine after it is installed. Refer to UENR1312, PL83 Pipelayer Hydraulic System Specifications, Systems Operation, Testing and Adjusting Manual. Perform the applicable test and adjust procedures listed below from the PISTON PUMP (STEERING) - TEST AND ADJUST section of UENR1312. Understand WARNING AND SPECIFICATIONS sections before performing any work.

** ?TEST PREPARATION ? CHARGE PRESSURE?
** ?TEST PROCEDURE ? CHARGE PRESSURE?
** ?ADJUSTMENT PROCEDURE ? CHARGE PRESURE? (Only if out of specification)
** ?TEST PREPARATION ? MECHANICAL NEUTRAL POSITION FOR THE ACTUATOR PISTON?
** ?TEST PROCEDURE ? MECHANICAL NEUTRAL POSITION FOR THE ACTUATOR PISTON?
** ?ADJUSTMENT PROCEDURE ? MECHANICAL NEUTRAL POSITION FOR THE ACTUATOR PISTON?
** ?TEST PREPARATION - NEUTRAL POSITION FOR THE STEERING PUMP CONTROL VALVE?
** ?TEST PROCEDURE - NEUTRAL POSITION FOR THE STEERING PUMP CONTROL VALVE?
** ?ADJUSTMENT PROCEDURE - NEUTRAL POSITION FOR THE STEERING PUMP CONTROL VALVE?

Note: The jamb nut should be tightened to 80 Nm (60 ft-lbs).

Image1.10.1

11) Update Powertrain software and then download Product Status Reports (PSRs) in pdf format. Name the file using the following convention: "Machine serial number and Service Letter Number and After Powertrain Installation". This file will be utilized in a future step.

12) Give the Product Status Report files downloaded in Step 3, Step 11, and the Pictures taken in Steps 6A to your Dealer Technical Communicator (TC) along with machine serial number, this Service Letter program number, and CPI number 400374.

13) Request the Dealer TC to submit the information through CPI Feedback within the Service Information Management System (SIMSi). Include the following information:

.... Repair Date
.... Machine Serial Number
.... Machine Hours
.... Product Status Report (Before New Powertrain Software Is Installed)
.... Product Status Report (After New Powertrain Software Is Installed)
.... Pictures of Spring Collar Inspection
.... Part Number of Actuator Cartridge Installed During Repair

.

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*********** STEERING PUMP ACTUATOR CARTRIDGE REPLACEMENT *************
The steering pump actuator cartridge needs to be replaced by a qualified hydraulic repair shop that has previously rebuilt or repaired hydrostatic pumps with electro-hydraulic (EH) displacement controls.

The procedures applicable to steering pumps in UENR1313, PL83 Pipelayer Disassembly and Assembly Manual, should be used to replace the steering pump actuator cartridge.

The procedures specified in Special Instruction REHS9390, Bench Test Procedures should be used to bench test the 355-2401 steering pump after the steering pump actuator cartridge is replaced.

After the repaired steering pump passes bench testing, return to Step 8 in this Rework Procedure.