Product Support Program for Replacing the Relief Valve in the Boom and Stick Control Valves on E-Series Backhoe Loaders Caterpillar

Product Support Program for Replacing the Relief Valve in the Boom and Stick Control Valves on E-Series Backhoe Loaders [REBE1253]

HYDRAULIC SYSTEM

VALVE GP-CONTROL

Product Support Program for Replacing the Relief Valve in the Boom and Stick Control Valves on E-Series Backhoe Loaders

REBE1253-00

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09Oct2006

U-672

A-651

D-635

O-654

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE RELIEF VALVE IN THE BOOM AND STICK CONTROL VALVES ON E-SERIES BACKHOE LOADERS
5051 5117		PS42270

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42270" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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 AVSpare product analyst.

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TERMINATION DATE

31Oct2008

PROBLEM

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The boom raise and stick out relief valves used on E-Series machines was designed to use a nylon insert type seal on the adjusting screw lock nut for sealing between a retaining nut and a lock nut. This seal design has proven to be the cause of leaking from the end of the relief valve.

AFFECTED PRODUCT

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Model	Identification Number
420E	HLS00217, 219-226, 229-251, 255-264, 267-281, 284-302, 304-321, 324-342, 346-365, 367-388, 390, 392-400, 402-430, 432-440, 442-449, 451, 453-1025, 1027-1066, 1068-1073, 1076-1092, 1094-1176, 1178-1179, 1181-1182, 1184-1191, 1193-1205, 1207-1225, 1227-1234, 1236-1268, 1270-1280, 1282-1406, 1408-1475, 1477-1491, 1493-1508, 1510-1544, 1546-1558, 1560-1568, 1570-1652, 1654-1707, 1709-1744, 1746-1766, 1768-1786, 1788-1810, 1812-1819, 1821-1833, 1835-1842, 1844-1847, 1849-1853, 1856-1860, 1863-1878, 1880-1884, 1886-1897, 1899-1904, 1906-1916, 1918-1925, 1928-1935, 1937-1954, 1956-1986, 1988, 1991-1992, 1994-1999, 2002-2007, 2009, 2011, 2013-2015, 2017, 2019-2026, 2028-2030, 2032-2040, 2042-2047, 2050-2052, 2055, 2058-2068, 2071, 2074, 2076-2084, 2086-2090, 2093, 2095-2101, 2103-2105, 2107-2109, 2111-2116, 2120-2123, 2125-2130, 2133-2134, 2137, 2141-2142, 2144, 2146-2153, 2156-2159, 2226-2262, 2264-2266 KMW00154-00157, 159, 163-165, 167-222, 224-229, 231-237, 239-244, 246-252, 254, 256-506, 508-517, 519-531, 533-672, 674-721, 724-733, 735-752, 754-766, 769-777, 779-783, 785-795, 797-798, 801, 803-815, 817-818, 820-827, 829, 831, 834, 836-837, 840-841, 843-844, 847, 851, 853, 856, 858-859, 862-864, 867-868, 871-876, 883-886, 888, 891, 906-907, 909-910, 937-964
430E	DDT00223-00225, 227-238, 240-241, 243-323, 325-336, 338-339, 341-347, 349-353, 356-359, 361-372, 374-377, 379, 382, 393 EAT00234-00236, 238, 240, 245-246, 248-256, 259-342, 344-345, 347-459, 461-472, 474-479, 481-485, 487-514, 516-519, 522-530, 532-537, 540, 542, 544-545, 547-551, 553-554, 557-562, 564-565, 567-568, 578, 581
432E	BXE00260-00601, 603, 605-631, 633-635, 637-643, 645-646, 648-649, 651-671, 674-675, 677-679, 683-684, 687-689, 691-692, 695-697, 699-703, 705, 707, 709, 711, 713-714, 720-721, 728, 732, 736, 753
434E	FSH00280-00345, 347-407, 409-410, 412-413, 415-423, 426, 428-429, 432, 436, 453
442E	GKZ00290-00337, 339-341, 343-346, 348-351, 353
444E	LBE00311-00326, 333, 335, 338

PARTS NEEDED

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Qty	Part Number	Description
2	2570468	CAP
1	2663590	VALVE GP-P RLF-A
1	2663591	VALVE GP-P RLF-A

ACTION REQUIRED

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Remove the 269-1104 Relief Valve from the stick control valve and replace it with a 266-3590 Relief Valve. Also remove the 269-1105 Relief Valve from the boom control valve and replace it with a 266-3591 Relief Valve. Refer to the attached Rework Procedure.

Before Failure: Defined as replacing the relief valve before the relief valve. leaks. Use ?56? as the Warranty Claim Description Code and ?T? as the SIMS Description Code.

After Failure: Defined as replacing the relief valve after the relief valve leaks. Use ?96? as the Warranty Claim Description Code and ?Z? as the SIMS Description Code.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-4000 hrs, 25-48 mo	33.3%	50.0%	0.0%	0.0%	50.0%	50.0%

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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.

Rework Procedure

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1. Extend the boom and stick out and rest the bucket on the ground.
2. Relieve pressure from boom and stick circuits by stopping the engine, turning the key back to the ?on? position, and operating the boom and stick controls.
3. Remove floor mat.
4. Using the flat tip of a screwdriver, pry the lower boot up from each of the pilot pod towers.
5. Remove the rear floor plate.
6. Place a drip pan under boom and stick sections to catch any oil that might spill when the relief valves are removed.
7. Clean around stick and boom relief valves on topside of the valve bank to prevent contamination entering the relief valve cavities.
8. Remove top boom relief valve (second section from machine right side).
9. Quickly install new valve 266-3591 (315 bar).
10. Torque the relief valve to 70 NM (52 ft-lbs).
11. Remove top stick relief valve (third section from machine right side).
12. Quickly install new valve 266-3590 (290 bar).
13. Torque the relief valve to 70 NM (52 ft-lbs).
14. Clean off any oil so that a leak can be observed.
15. Fully cycle the boom and the stick cylinders to full stroke 10 times each at a low speed to remove air from the circuit.
16. Fully cycle the boom and the stick cylinders to full stroke an additional 20 times each at a high speed to verify that the relief valve is not leaking.
17. Check for oil leakage around new relief valves.
18. Add the tamper proof caps on the new relief valves for the boom and the stick control valve sections.
19. Replace floor plates, pilot pod towers and floor mat.