PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 315D EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 315D EXCAVATORS

Usage:

REBE4761-00

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22Dec2008

O-602

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 315D EXCAVATORS
5067 5147		PI31608

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31608" 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 "PI31608" 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:

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.

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COMPLETION DATE	TERMINATION DATE
30Jun2009	31Dec2009

PROBLEM

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The 317-1291 Boom Lowering Check Valves (BLCVs) need to be reworked on certain 315D Excavators. Changing the main poppet will improve hydraulic controllability in certain applications.

AFFECTED PRODUCT

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Model	Identification Number
315D LC	NCM00187-00191, 203-206

PARTS NEEDED

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Qty	Part Number	Description
2	4K1388	SEAL-O-RING
2	3108828	POPPET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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.

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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 1.0-hour job

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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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES

MODELS INVOLVED - 315D Excavators

Dear Caterpillar Product Owner:

The Boom Lowering Check Valves (BLCVs) need to be reworked on the products listed below. 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 22Dec2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 22Dec2008 Service Letter

Rework Procedure

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SAFETY OPERATIONS PRIOR TO BOOM LOWERING CHECK VALVES (BLCVs) REWORK PROCEDURE:
1) Place the machine on flat, level ground.
2) Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to Image 1.1.1.
3) Stop the engine.
4) Release the pressure in the boom down hydraulic circuit. Refer to Testing and Adjusting Manual, RENR9737, "Hydraulic System Pressure - Release Of Hydraulic Pressure From A Single Hydraulic Circuit".

Image1.1.1

DISASSEMBLY PROCEDURE:

NOTE: Refer to Image 1.2.1 for Item locations.

5) Loosen the 311-1906 Plug (Item 25).
6) Slowly remove the 311-1906 Plug to collect the following parts:
a) Shims 4J-7386 and/or 211-7944 (Items 16 and/or 2). Carefully handle the exact quantity of shims which must be reused later at step 8 (the shims may remain inside the 311-1906 Plug and/or onto the face of the 311-1912 Guide (Item 26).
b) 311-1912 Guide (Item 26).
c) 211-4183 Spring (Item 13). Carefully handle this spring which must be reused at step 10.
d) 311-1876 Valve (Item 24).
e) 315-4511 Poppet (Item 27).
f) Pin part of 294-4473 Guide Assembly (Item 21). Carefully handle the pin which must be reused at step 9.

Image1.2.1

ASSEMBLY PROCEDURE:
7) Replace the 4K-1388 Seal-O-Ring (Item 36) by the same part number onto the 311-1906 Plug (Item 25).
8) Insert all the shims, formerly removed in step 6, inside the 311-1906 Plug (Item 25).
9) Place the 311-1912 Guide (Item 26) inside the 311-1906 Plug (Item 25).
10) Install the 211-4183 Spring (Item 13), that was removed in step 6, onto the 311-1912 Guide (Item 21).
11) Keep this assembly for later use.
12) Insert the 311-1876 Valve (Item 24) inside the bore of the new 310-8828 Poppet. (Item 27)

Image1.3.1

13) Install the plug assembly obtained in step 11 into the valve.
14) Tighten the 311-1906 Plug (Item 25) to a torque of 190 +/- 19 Nm.
15) Repeat step 5 through 15 for the second BLCV.
16) Start the engine.
17) Slowly move the joystick to raise the boom 1 meter off the ground and then lower it back down again. Repeat this operation 10 times to purge the air.