PRODUCT SUPPORT PROGRAM FOR REWORKING THE MAIN HYDRAULIC PUMP ON CERTAIN 330D, 330D L, 330D MH, 345C, 345C L, AND 345C MH HYDRAULIC EXCAVATORS IN THE CASE OF LOOSE SERVO PISTON. Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE MAIN HYDRAULIC PUMP ON CERTAIN 330D, 330D L, 330D MH, 345C, 345C L, AND 345C MH HYDRAULIC EXCAVATORS IN THE CASE OF LOOSE SERVO PISTON.

Usage:

REBE6182-00

21Dec2010


U-512
A-421
D-450
O-449

 
After Failure Only
  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE MAIN HYDRAULIC PUMP ON CERTAIN 330D, 330D L, 330D MH, 345C, 345C L, AND 345C MH HYDRAULIC EXCAVATORS IN THE CASE OF LOOSE SERVO PISTON.

5084 5070
PS51950
NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51950" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.


TERMINATION DATE

31Dec2012

PROBLEM

The existing servo piston can become loose in the main hydraulic pump on certain 330D, 330D L, 330D MH, 345C, 345C L, and 345C MH Excavators. If the servo pin is loose, it will cause one of the track motors to work slower and consequently the machine will drift in one direction.

AFFECTED PRODUCT

Model Identification Number
330D ERN00241, 244-251, 254-274, 277-283, 285, 288-290, 292-298, 300-303, 305, 307-308, 310-311, 314-319

GGE00207, 209-219, 221-227, 229-236, 238-252, 254-257, 259-266, 268-289, 291-293, 295-307, 309-328, 330-352, 354-385, 387, 389, 391-392, 394-401, 403-412, 414, 416-418, 420-438, 440-452, 454-455, 457-466, 468, 470-471, 473-480, 482, 484-486, 488-499, 502-511, 513-523, 525-528, 532-534, 537-542, 544-551, 553-561, 563-569, 571, 573-575, 577-579, 581-583, 585-598, 602-606, 609-620, 624-635, 637-638, 640-664

RAS00176-00215, 217-219, 221-243, 245-250, 252-254, 256-280, 282-299, 301-312, 314-323, 325-331, 333-342, 344-364, 366-388, 390-404, 406-415, 417-420, 422, 424-428, 430-438, 440-445, 448-449, 451-492, 494-502, 504-522, 524-526, 528-531, 533-539, 541-547, 549-563, 565-567, 569, 571-573, 575-577, 579, 581-586, 588-592, 594-595, 597-598, 601, 603, 605-607, 609-612, 614, 616, 618-619, 621, 623-632, 634-636, 638-655, 657, 659-674, 676, 682, 684-697, 699-705, 707-721, 723-726, 728-737, 739-744, 746-750, 752-754, 756-758, 760-762, 764-773, 776-785, 787-797, 799-800, 802-804, 807-810, 812-814, 816-817, 819-824, 826-829, 831, 833-834, 836-838, 840-851, 853, 855-859, 861-867, 870, 872, 874-875, 877-879, 881, 885-886, 888-890, 892, 894-901, 903-906, 908, 911, 913-922, 924-960

THJ00241-00242, 244-270, 272-275, 277-292, 294-307
330D L HAS00251-00324

LRM00251-00286

T2Y00231-00273, 276-281, 283-295, 297-316, 318-333, 335-338, 341-342, 344-354, 357-358, 361-362, 365-378, 380-385, 388-392, 395-399, 401-403, 405-407
330D MH  PEL00172
330D OEM  D3D00101-00161, 163-175, 177-189, 191-233, 235-263, 265, 277
345C GPH00139-00207, 209-222, 224-233, 235-268, 270, 272-286, 288, 290-292, 294-295, 297-319, 321-322, 324-341, 343-353, 355-360, 362-366, 368-370, 372-373, 375-376, 378-379, 381-398

SPC00225-00236, 238-261, 263-265
345C L FPC00125-00146

GCL00256-00272, 274-276

LYS00133-00150, 152-154, 156-160, 162, 164-173, 175-178, 180-186
345C OEM B6N00103, 111-118, 120-126, 128-129, 131-135, 137

NRF00100-00104

PARTS NEEDED

Qty

Part Number Description
1 7I8172 RING-BACK UP
1 1091296 SEAL-O-RING
16 2069290 SEAL-O-RING
2 2069300 SEAL-O-RING
1 3264415 GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-6000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
6001-8000 hrs,
49-60 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 20.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
In order to prevent contamination and allow proper servo piston thread inspection, remove the pump from the machine and handle this rework in a controlled environment. Refer to the machines Disassembly and Assembly Manual for removal and installation procedures.

In order to properly tighten the servo-piston, a dedicated tool needs to be fabricated. Refer to the photograph and drawings at the end of the rework procedure.
 
Step 1: Clean and Identify

Before starting to remove parts from the pump, identify them as to which side of the pump they have come off. Identify them as regards to driven and drive side or as appropriate.
Image1.2.1
 
Step 2: Removal of Regulators

Remove the regulators by undoing the 4 bolts [Item No 1], using a 6mm AF hex key.
Image1.3.1
 
With both regulators removed check to see which servo piston assembly is loose.
Image1.4.1
 
If only one servo piston is loose, perform Steps 4 to 11 to the side that is loose.
 
Step 3: Removal of Pump Coupling Flange

In order to slide out the servo piston from the pump body, remove the pump coupling flange using a 10mm Allen socket (11 bolts Items No 2 to be removed).
Image1.6.1
 
Step 4: Removal of Maximum Flow Adjustment Blocks

Remove the maximum flow adjustment block using a 10mm Allen key (remembering which one is drive and which is driven).
Image1.7.1
 
Step 5: Removal of Stopper

Insert a M5x30mm SHCS into the stopper situated behind the maximum flow adjustment block.
Image1.8.1
 
Using a pair of pliers, remove the stopper taking care not to damage the o-ring seal and the backup ring around it.
Image1.9.1
Image1.9.2
 
Step 6: Removal of the Servo Piston and Tilting Bush

Undo the servo piston using a 17mm AF hex key. Once the servo piston is undone, slide it out of the bore being careful not to damage it or drop the tilting bush.
Image1.10.1
Image1.10.2
Image1.10.3
 
Remove the tilting bush making note of which way round it goes as one side is machined and the other is not.
Image1.11.1
 
Once this is out this enables the threads of the tilting bush and servo piston to be cleaned thoroughly with a suitable degreasing fluid. It is recommended to clean the threads with a plastic brush. Make sure that these threads are as clean as possible and all existing retaining compound has been removed in order for the loctite 648 (Retaining Compound) to be able to adhere properly.
Image1.12.1
Image1.12.2
Image1.12.3
Image1.12.4
 
Step 7: Installation of the Cleaned Tilting Bush

Locate the tilting bush pivot in the pump swash plate receptacle. Make sure to locate the tilting bush such that its machined face (shiny face) points towards the servo-piston bigger diameter.
Image1.13.1
Image1.13.2
 
Step 8: Application of Loctite

Apply a small amount of Loctite 648 (in a line) from the tilting bush leaving the last 2 or 3 threads with none on. (See Image 1.14.1)

Do not apply excessive loctite to the threads. When tightened the machined face of the tilting bush must have NO loctite against this face. Otherwise this could compromise the bond between the two parts.
Image1.14.1
 
Step 9: Assembly of Servo Piston

The servo piston can be tightened by hand using a 17mm AF Hex key.
Image1.15.1
 
In order to properly locate the servo piston locking tool, slide the servo piston such that the tilting bush is located in the middle of the pump body cavity.
Image1.16.1
 
Insert the locking tool on top to the centered tilting bush. Make sure the 4 legs are surrounding the tilting bush upper surface and the locking tool lays vertically in the pump body cavity.
Image1.17.1
 
Pre-install the reaction plate against the pump body by finger tightening the 8T-7547 M8 Bolts (3). As a result of that operation, the reaction plate should still move in a horizontal plane but not vertically. This is very critical as this freedom will allow further adjustment to prevent play between the tilting bush, the locking tool and the reaction plate. You can now tighten the 8T-4184 M12 Bolt to a torque of 80 Nm in order to secure the reaction plate against the locking tool.
Image1.18.1
 
Smoothly apply force on the reaction plate towards the locking tool to eliminate play between them but also the play versus the tilting bush.
Image1.19.1
 
Tightening the 8T-7547 M8 Bolts (3) to a torque of 20 Nm is the final stage of the servo piston tool installation.
Image1.20.1
 
The servo piston must then be tightened to 480Nm using a torque wrench and a 17mm AF Hex drive.
Image1.21.1
 
Remove the servo piston tool from the pump body.

Step 10: Assembly of the Servo Piston Stopper

Place a new 109-1296 O-Ring Seal and 7I-8172 Back Up Ring into the stopper groove, back up ring located to the outside of the pump body.

Insert the stopper making sure that it is inserted squarely so as not to damage the o-ring and back up ring.
Image1.22.1
 
Step 11: Assembly of the Maximum Flow Adjustment Block

Install the maximum flow adjustment block making sure that the correct one goes on the side that it was removed from. The bolts should be tightened to 98Nm using a 10mm drive bit.
Image1.23.1
 
Step 12: Installation of the Regulators (Important to ensure free back arm is correctly fitted to tilting bush)

It is advisable that the driven regulator must be replaced first due to the drive regulator obstructing. Make sure that the tilting bushes are central to the bores. Replace the 206-9300 O-Ring and the eight 206-9290 O-Rings per regulator.
Image1.24.1
 
The feedback arm must be located onto the tilting bush. This is a critical step as damage can occur to the arm if it is not correctly seated on the pin. To fit the arm onto the pin you must first place the regulator onto the pump.

While lifting up the back of the regulator, use a 150mm [6"] steel rule to move the feedback arm backwards and forwards to find the pin. While doing this gradually raise the regulator up at an angle to lift it over the pin. Keep the front of the regulator on the pump case.
Image1.25.1
Image1.25.2
 
Once the feedback arm is on the pin, lower the regulator down slightly and double check by trying to move the arm backwards and forwards. If it is on and the bushes are in the center of the bores, then the arm should not move either way. Before lowering the regulators down completely double check all o-rings are still in place. Tighten the 4 bolts [Item No 1] to 29Nm. Repeat this step for the drive regulator.
Image1.26.1
 
Step 13: Install the Pump Coupling Flange

Install a new 326-4415 Flange Gasket.

Install the pump coupling flange using a 10mm Allen socket (11 bolts items No 2 to be tightened to 98 Nm).

Make sure before running the pump to leave it for 12-24 hours in order for the loctite to properly cure.
Image1.27.1
Image1.27.2
 
SERVO PISTON TOOL PICTURE AND DRAWINGS
Image1.28.1
Image1.28.2
Image1.28.3
Image1.28.4
Image1.28.5
Image1.28.6
Image1.28.7
Image1.28.8
 
 

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