PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE STEERING TILLER SPRING ON CERTAIN PL72, PL83, AND PL87 PIPELAYERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE STEERING TILLER SPRING ON CERTAIN PL72, PL83, AND PL87 PIPELAYERS [UEBE0548]

ELECTRICAL AND STARTING SYSTEM

SENSOR GP

PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE STEERING TILLER SPRING ON CERTAIN PL72, PL83, AND PL87 PIPELAYERS

UEBE0548-01

Show/hide table

22Apr2020

(Revised 08May2020)

U-232

D-217

O-217

Show/hide table

Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE STEERING TILLER SPRING ON CERTAIN PL72, PL83, AND PL87 PIPELAYERS
7750 1408		PI11244

Show/hide table

NOTE:

AVSpare’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 AVSpare.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI11244" 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 "PI11244" 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

NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.

Show/hide table


NOTE:	This Revised Service Letter replaces the 22Apr2020 Service Letter. Changes have been made to the Parts Stock - Action Required and the Rework Procedure.

Show/hide table

PROBLEM

Show/hide table

The steering tiller spring used on certain PL72, PL83, and PL87 Pipelayers needs to be checked for proper function. The existing spring may not fully return the steering tiller to neutral in all circumstances. As a result, the machine could steer without command, which may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. If the spring does not pass inspection, it will need to be replaced.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
PL72	P7200120-00133 P7300121-00132
PL83	CB200120-00226 DLW00120
PL87	TEC00100, 120-246 ZAC00120-00154

Show/hide table

*****Group 2*****
PL72	P7200134-00137, 400-437 P7300400-00415
PL83	CB200227-00268, 400-477
PL87	TEC00247-00286, 400-549

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
1	2921357	SPRING (After Failure Only)
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*****
1	2921357	SPRING (After Failure Only)
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

****Parts Stock ****

Replace the 292-1357 Spring in all 360-5122 Steering Tillers in dealer part stock with date codes between 01Jan18 and 31Dec19. Refer to Image 1. Note format for date code is MM-DD-YY. Refer to the attached rework procedure for instructions, beginning at Step 7.

NOTE: Since no efficient means for testing tillers exists when not installed on a machine, it is most practical to replace all springs on tillers in dealer parts stock inventory.

NOTE: All 292-1357 Springs stocked in the parts network have been checked to ensure conformance.

Image1

****Affected Product****

Show/hide table

Group 1

If dealer service records indicate that the 360-5122 Steering Tiller was replaced between 01Jan18 and 10Apr20, this service letter should be applied. Refer to the attached Rework Procedure for instructions.

Group 2

All machines in this group should have this service letter applied. Refer to the attached Rework Procedure for instructions.

NOTE: All 292-1357 Springs stocked in the parts network have been checked to ensure conformance.

Show/hide table

OWNER NOTIFIAVSION

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

****Parts Stock****

One half hour of labor and one 292-1357 Spring is allowed for each 360-5122 Steering Tiller in dealer parts stock that needs to be reworked.

****Affected Product****

Show/hide table

AVSpare		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 0.5-hour job for Group 1
The half hour called out above is to search service records to identify machines that have had tillers replaced during the affected timeframe. One hour of labor is allowed to test the tiller according to the attached Rework Procedure if service records show tiller was replaced during time in question. When necessary, an additional one hour of labor is allowed for an after-failure repair where the spring must be replaced.

Show/hide table

AVSpare		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 1.0-hour job for Group 2
The hour called out above is to test the tiller according to the attached Rework Procedure. When necessary, an additional one hour of labor is allowed for an after-failure repair where the spring must be replaced.

Show/hide table

PARTS DISPOSITION

Show/hide table

****Parts Stock****

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

Show/hide table

****Affected Product****

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

Show/hide table

EXAMPLE COPY OF OWNER NOTIFIAVSION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR CHECKING THE STEERING TILLER SPRING ON CERTAIN PL72, PL83, AND PL87 PIPELAYERS

MODELS INVOLVED - PL72, PL83, and PL87 Pipelayers

Dear Cat Product Owner:

The steering tiller spring needs to be inspected and potentially reworked on the products listed below. The existing spring may not fully return the steering tiller to neutral after a steering command and could, 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 AVS.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 22Apr2020 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.

AVSpare Inc.

Identification #(s)

Attached to 22Apr2020 Service Letter

Rework Procedure

Show/hide table

1. Connect Cat ET to the machine and navigate to the Status screen to read the tiller position duty cycles:

o Steering Control Position Sensor #1 Duty Cycle
o Steering Control Position Sensor #2 Duty Cycle

NOTE: The following is to understand the ?play" or "backlash" the handle has around neutral. This only requires a very light touch and should only require minimal effort to move.

2. Center the tiller, take your hand off of the tiller, then lightly pull the tiller backward until you until you begin to feel the resistance of the spring and record the duty cycles from ET:

(A) Sensor 1 _____%
(B) Sensor 2 _____%

3. Center the tiller, take your hand off of the tiller, then lightly push the tiller forward until you begin to feel the resistance of the spring and record the duty cycles from ET:

(C) Sensor 1 _____%
(D) Sensor 2 _____%

4. Calculate the difference between the 2 readings by subtracting the values:
(E) Measure A ? Measure C = _____%
(F) Measure B ? Measure D = _____%

5. If value (E) or (F) is 5.0% or less, the steering tiller is acceptable for continued use and does not need to have the internal spring replaced.

If value (E) or (F) is greater than 5.0%, it is necessary to replace the 292-1357 Spring inside the steering tiller, as outlined in the following steps.

6. Only if value (E) or (F) above is greater than 5.0%, reference the appropriate document to remove the steering tiller from the machine:

PL83 and PL87 Pipelayers
Disassembly and Assembly - Machine Systems Media Number - UENR4142

PL72 Pipelayers
Disassembly and Assembly - Machine Systems Media Number - UENR4133

7. In order to replace the spring inside the steering tiller, some disassembly is required. First, remove the two screws that hold the sensor on the bottom of the steering tiller as shown in Image 1.7.1 below.

Image1.7.1

8. Support shaft from below and press key on the box side as shown in Image 1.8.1 below.

Image1.8.1

9. Use chisel or punch to remove key from shaft. Refer to Image 1.9.1.

Image1.9.1

10. Remove 4 bolts from cover and remove cover. See Image 1.10.1.

Image1.10.1

11. Remove the shaft and spring assembly from the housing. Slide the old 292-1357 Spring off the shaft. Install the new 292-1357 Spring per Illustrations 1.11.1 and 1.11.2. Note position of spring legs around the center pin.

Image1.11.1

Image1.11.2

12. Apply a light coating of Lubriplate to both sides of the spacer and place in housing, as shown in Image 1.12.1.

Image1.12.1

13. Assemble the updated shaft and spring assembly into the housing. Ensure proper orientation of legs of the spring to the pin in the housing. Refer to Image 1.13.1 below.

Image1.13.1

14. Apply a thin film of Lubriplate to both sides of the washer as shown in Image 1.14.1 below before re-installing it.

Image1.14.1

15. Place Housing 'A' over the dowels in Housing 'B' and push the two housings together. Refer to Image 1.15.1.

Image1.15.1

16. Apply Blue Loctite 243 (or equivalent for geographic region) to the four bolts shown in Image 1.16.1 below before installing them. Tighten to a torque of 4.5 ft-lbs (6 Nm).

Image1.16.1

17. Install the sensor on the box, making sure the tang on the shaft fits into the slot on the sensor. Apply Loctite 243 to the bolts. Thread the bolts through the sensor an into the box. Tighten to a torque of 1.7 ft-lbs (2.25 Nm). Refer to Image 1.17.1.

Image1.17.1

18. Re-install the key removed in Steps 8 & 9.

19. Re-install the steering tiller on the machine, referencing the same service literature that was used for removal.

20. Repeat the test procedure outlined in Steps 2 - 5 to ensure that the updated steering tiller performs acceptably.

21. If the 292-1357 Spring was replaced, re-calibrate the steering tiller.

To access the calibration procedures for the Transmission ECM, establish the connections of the Cat ET to the machine. Navigate to the calibration screen by clicking "Service" on the tool bar and then clicking "Calibrations". Select the desired calibration procedure that is required. Click on the "Start" button at the bottom of the screen.

Once the steering calibration is selected, the Cat ET will guide you through the calibration procedure.

The Cat ET will list initial machine conditions that must be satisfied before the ECM will allow the calibration procedure to continue. Follow the specific instructions on the display in order to complete the calibration procedure.