New Linkage For Hoist Control Group Needs To Be Installed On Certain D40D Articulated Dump 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 "PI3517" 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 "PI3517" 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

The existing hoist control group, with a flexible cable, may stick or cause operational difficulties. A new linkage needs to be installed and modifications made so that the control lever easily returns to the neutral or hold position.

Affected Product
Model & Identification Number

D40D (2JJ1-80)

Parts Needed

Dealers will need to order'parts for this Program.

2 - 3B4611 Pin Cotter

2 - 3B4617 Pin Cotter

4 - 5B9079 Lock Nut

4 - 2F8616 Nut

2 - 2L1701 Cap Screw

2 - 4L6454 Bolt

2 - 8T4122 Washer

2 - 8T4224 Washer

2 - 8T4896 Washer

1 - 8T5360 Washer

2 - 2U2475 Flat

1 - 2U2606 Pin

2 - 2U2634 Washer

4 - 2U5283 Rod End

1 - 2U6084 Plate

1 - 2U6086 Shaft

1 - 2U6088 Rod

2 - 2U6089 Link

1 - 2U6090 Lever

1 - 2U6091 Bush

2 - 2U6094 Spacer

1 - 2U6686 Spool Kit

2 - 3U7777 Rod End

1 - 7U4049 Link

1 - 7U4051 Lever

2 - 7U7684 Pin Clevis

Action Required

See the attached procedure.

Owner Notification

Not Applicable

Service Claim Allowances

NOTE: This is a 6-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.

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Rework Procedure)

Rework Procedure

1. Park the truck with the dump body fully lowered.

2. Remove Items (1), (2), (3), (4), (5), (6), (7), and all mounting hardware as shown in Illustration 1. Lever 1 and Trim 2 will be used again.

3. Assemble Levers (1) and (8). Use the hole in Lever (1) as a guide to drill an 8 mm (.315") diameter hole through Lever (8). See Illustration 2.

4. Separate Levers (1) and (8). Install the levers in the cab with Trim (2) and Pin (9). See Illustration 3.

5. Install the 2U6686 Spool Kit. Install Bosses (10) and Plate (11). Use the original mounting hardware. See Illustration 4.

6 Assemble Items (14) through (21) and assemble Shaft (21) to Brackets (13) on the front frame main crossmember as shown in Illustration 5.

NOTE: Brackets (13) are installed on all of the affected product.

7. Complete the linkage between Hoist Lever (8) and the hoist control valve by installing Items (22) through (34). See Illustration 6.

Illustration 1 - Existing Control Arrangement

Illustration 2 - Assembly Detail For Levers (1) and (8)

Illustration 3 - Lever Installation

Illustration 4 - Revised 7U4518 Mounting Gp. for Hoist Valve

Illustration 5 - Shaft Installation

Illustration 6 - Hoist Linkage Installation