Counterbalance Valve Needs To Be Installed In The Body Hoist Hydraulic System Of Certain D40D Articulated Trucks Caterpillar

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.

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3564" as the Part Number, "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 "PI3564" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Completion Date

Termination Date

Problem

A counterbalance valve needs to be installed in the body hoist hydraulic system of certain D40D Articulated Trucks. The valve overcomes cylinder void problems which may be experienced at high body angles.

Affected Product
Model & Identification Number

D40D (2JJ1-81,2JJ85)

Parts Needed

Dealers will need to order parts for this Program.

2 - 3J1907 Seal

3 - 4J8265 Nut

2 - 0L2070 Cap Screw

2 - 2M9780 Seal-O ring

1 - 8T1887 Clip

1 - 8T1888 Clip

3 - 8T4896 Washer

1 - 2U7619 Valve Group

1 - 2U7620 Tube Assembly

1 - 2U7621 Tube Assdmbly

1 - 2U7622 Tube Assembly

1 - 2U7623 Bracket

1 - 2U7625 Hose Assembly

1 - 2U7626 Hose

4 - 6U0455 Lashing Tie

4 - 6V8397 Seal

1 - 6V8636 Connector

2 - 6V8640 Connector

1 - 6V8724 Elbow

6 - 6V9746 Seal-O ring

1 - 6V9836 Tee

Action Required

See the attached procedure.

Owner Notification

Not Applicable

Service Claim Allowances

NOTE: This is an 8-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.

Parts Disposition

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

Attach. (1-Rework Procedure)

Rework Procedure

Oil filled hoses are disconnected during the following procedure. catch any oil which is released in a suitable container and clean up any spills.

Use AWS E7018 electrodes or equivalent.

1. Raise and secure the dump body with the body prop. See the Service Manual.

2. Remove tubes (1) and (2) shown in Illustration 1. The mounting hardware will be reused. The tubes will not be reused.

3. Refer to Illustration 2. Install adapters (3) with o- rings (4) in counterbalance valve (8). Attach bracket (5) with bolts, nuts, and washers (6), (7), and (9). Position the bolts in the center of the bracket slots.

4. Refer to Illustration 3. Install tubes (10), (11), and (13); counterbalance valve (8); and o-rings (12). Tighten the tube fittings and secure with the original mounting hardware. Ensure that the flange of bracket (5) is flush with the top of the frame.

5. Cover the ports on the counterbalance valve (8) and plug weld bracket (5) to the frame. Do not weld around the outside of the bracket. Clean and paint as required.

6. Refer to Illustration 4. Disconnect steering neutralizer drain hose (14) from manifold (16) located on the hydraulic module at the right side of the tractor. Install tee (15). Connect hose (18) to tee (15) with o- ring (17).

7. Refer to Illustration 5. Complete and secure the piping arrangement as shown. The counterbalance valve is preset and does not require any adjustment.

8. Fully raise the dump body and put the body prop in the storage position. Raise and lower the body to remove any air from the hoist hydraulic system.

9. Fully lower the body and check the hydraulic oil level. Fill as necessary.

Parts List For Illustrations 1-5

Illustration 1

Illustration 2

Illustration 3

Illustration 4

Illustration 5