PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 165-9579 RELIEF VALVE GROUP ON CERTAIN 365B L, 365B L SERIES II, 385B, 385B L, 385C, 385C L, AND 385C OEM EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 165-9579 RELIEF VALVE GROUP ON CERTAIN 365B L, 365B L SERIES II, 385B, 385B L, 385C, 385C L, AND 385C OEM EXCAVATORS

Usage:

REBE5979-01

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13Jun2011

(Revised 04Jan2012)

U-238

A-195

D-6

O-213

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 165-9579 RELIEF VALVE GROUP ON CERTAIN 365B L, 365B L SERIES II, 385B, 385B L, 385C, 385C L, AND 385C OEM EXCAVATORS
7750 5069 5117		PI10864

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10864" 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 "PI10864" 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 13Jun2011 Service Letter. Changes have been made to the Affected Product.

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PROBLEM

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The 165-9579 Relief Valve Group needs to be replaced on certain 365B L, 365B L Series II, 385B, 385B L, 385C, 385C L, and 385C OEM Excavators that are equipped with the combined auxiliary circuit control arrangement. The outside body of the existing 155-4847 Relief Valve may fail, resulting in an uncontained failure of the relief valve which in conjunction with other factors or circumstances, could result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
365B L	9PZ00491, 494, 498, 504, 508, 516-517, 520-522 9TZ00534, 536-538, 540
365B L II	DER00101, 106-107, 109, 111-112, 117-119, 149, 157, 160, 163, 190-193, 214, 221, 229, 251, 260 JMB00285, 307, 325, 342-343, 348-349, 374, 390, 401, 405, 433, 444, 447, 461, 467-468, 499, 512, 529, 539

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*****Group 2*****
385B	RCD00152-00153, 159-160, 169, 175, 181, 187, 205, 215, 244
385B L	FDL00151-00153, 210, 213, 223, 229-230, 232, 234-237, 261-262, 265, 273, 275, 277
385C	KKK00147, 158, 171, 195
385C L	EDA00191, 214, 235, 274, 313, 331, 340, 416, 420, 431, 459, 468, 478, 487, 490, 503, 511, 513, 518, 522, 535 KGB00277-00278, 284-286, 290-291, 296, 298, 300, 302, 307, 310, 312-314, 320, 327, 343, 345-346, 349-350, 365-366, 371-374, 381, 384, 388, 391, 393-394, 399, 407, 411-413, 420, 423, 425-426, 431, 433, 445-446, 449, 452-453, 463, 485, 489-491, 493, 497 SBE00204-00205, 223, 240, 242, 247, 250, 258, 262-263, 265-266, 299, 320-321, 338-341, 348-349, 368, 372-373, 390-391, 393-396, 401-403, 435-438, 451 T2E00304, 310, 312-313, 315, 318, 338
385C OEM	MSF00114

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	1P3705	SEAL-RECTANGULAR
2	1P3706	SEAL-RECTANGULAR
2	0951603	SEAL-O-RING
1	3527205	VALVE GP-RLF -C
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.
*****Group 2*****
2	1P3705	SEAL-RECTANGULAR
2	1P3706	SEAL-RECTANGULAR
1	1609186	SEAL-KIT
1	3527205	VALVE GP-RLF -C
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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Replace the existing 165-9579 Relief Valve Group with a new 352-7205 Relief Valve Group. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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 4.0-hour job for Group 1

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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 3.0-hour job for Group 2

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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 NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 165-9579 RELIEF VALVE GROUP ON CERTAIN EXCAVATORS

MODELS INVOLVED - 365B L, 365B L SERIES II, 385B, 385B L, 385C, 385C L, and 385C OEM Excavators

Dear Caterpillar Product Owner:

The 165-9579 Relief Valve Group needs to be replaced on the products listed below. The outside body of the existing 155-4847 Relief Valve may fail, resulting in an uncontained failure of the relief valve which in conjunction with other factors or circumstances, could result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Caterpillar 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 13Jun2011 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 13Jun2011 Service Letter

Rework Procedure

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Group Number 1

1. Release the pressure in the hydraulic tank. Refer to disassembly and assembly manual, "Hydraulic System Pressure - Release".

2. Place the 165-9576 and 165-9577 Ball Valve Assemblies into the closed position. Refer to Image1.1.1.

3. Clean all of the components around the relief valve group in order to avoid contamination.

4. Remove the eight 8T-5092 Bolts (Item 3) that maintains the 165-9579 Relief Valve Group and ball valve assemblies to the 152-9198 Support.

5. Remove the four 7X-2556 Bolts (M16) that connect the 149-6557 Tube Assembly on the 149-6556 Block (Item 2).

6. Remove the two 8T-4648 Bolts that attach the 152-9198 Support Assembly to the 187-5899 Support Assembly in order to remove the 149-6557 Tube Assembly and 165-9579 Relief Valve Group. Refer to Image1.1.1 (Item 4).

7. Remove the 149-6557 Tube Assembly from the 165-9579 Relief Valve Group.

8. Install new 1P-3706 Seals onto the 149-6557 Tube Assembly.

9. Install the 149-6557 Tube Assembly to the new 352-7205 Relief Valve Group. Refer to Image1.1.4.

10. Install the new 352-7205 Relief Valve Group, 7I-8110 Plates, and ball valve assemblies to the support assembly with 8 bolts and washers. Ensure that the seals are placed correctly. Refer to Image1.1.3.

12. Reinstall the 149-6557 Tube Assembly to the 149-6556 Block (Item 2). Refer to Image1.1.2.

Image1.1.1

Image1.1.2

Image1.1.3

Image1.1.4

Group Number 2

1. Release the pressure in the hydraulic tank. Refer to disassembly and assembly manual, "Hydraulic System Pressure - Release".

2. Remove the cover. Refer to Image2.1.1 (Item 1).

3. Place the 175-1814 and 160-0964 Ball Valve Assemblies into the closed position. Refer to Image2.1.2.

4. Clean all of the components around the 165-9579 Relief Valve Group in order to avoid contamination.

5. Remove the four 8T-4175 Bolts that connect the 176-4505 Tube Assembly to the 165-9579 Relief Valve Group. Refer to Image 2.1.3 (Item 2).

6. Remove the eight 8T-7930 Bolts (Item 3) that maintains the 165-9579 Relief Valve Group and ball valve assemblies on the 176-4519 Support. Refer to Image2.1.3 (Item 4).

7. Remove the 165-9579 Relief Valve Group. Refer to Image2.1.4.

8. Install the new seals and the 160-9999 Plate Assembly to the new 352-7205 Relief Valve Group. Ensure that the seals are placed correctly. Refer to Images2.1.3. and 2.1.4.

9. Install the new 352-7205 Relief Valve Group, the 176-4508 Plate, and the ball valve assemblies to the support assembly with 8 bolts and washers. Refer to Images2.1.3. and 2.1.4.

10. Install a new 1P-3706 Seal on to the 176-4505 Tube Assembly.

11. Install the tube assembly onto the new 352-7205 Relief Valve Group with the four 8T-4175 Bolts. Refer to Images2.1.3. and 2.1.4.

12. Install the cover.