PRODUCT SUPPORT PROGRAM FOR REPAIRING THE IMPLEMENT CONTROL VALVE ON CERTAIN 416D, 420D, 420D IT, 424, 424D, 428D, 430D, 430D IT, 432D, 442D, AND 446D BACKHOE LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE IMPLEMENT CONTROL VALVE ON CERTAIN 416D, 420D, 420D IT, 424, 424D, 428D, 430D, 430D IT, 432D, 442D, AND 446D BACKHOE LOADERS [REBE1914]

HYDRAULIC SYSTEM

VALVE GP-BANK

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE IMPLEMENT CONTROL VALVE ON CERTAIN 416D, 420D, 420D IT, 424, 424D, 428D, 430D, 430D IT, 432D, 442D, AND 446D BACKHOE LOADERS

REBE1914-01

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12Jul2007

(Revised 26Oct2007)

U-319

A-260

D-269

O-290

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE IMPLEMENT CONTROL VALVE ON CERTAIN 416D, 420D, 420D IT, 424, 424D, 428D, 430D, 430D IT, 432D, 442D, AND 446D BACKHOE LOADERS
5051		PS51328

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51328" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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NOTE:	This Revised Service Letter replaces the 12Jul2007 Service Letter. Changes have been made to the FDP serial number range in the Affected Product. Changes have also been made to the Parts Needed and Rework Procedure.

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TERMINATION DATE

31Jul2011

PROBLEM

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The 6E-4317 Spring used on the compensator spool of certain implement control valves can fail because the compensator vent slots were manufactured off location in some control valve bodies. The lack of a vent slot allows pressure to build on the front of the compensator spool. The spring on the other end of the spool is forced to its solid length and can become crushed by the force on the spool as system pressure increases. The failure typically occurs over an extended period of time while operating under these conditions.

AFFECTED PRODUCT

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Model	Identification Number
416D	B2D00173, 181, 345, 446-2701 BFP13607, 13670, 13683-17198 BGJ01118-01315
420D	BKC00920-00922 FDP20047-20048, 20080, 20097-20184, 20186-27266
420D IT	BLN10906, 10915-13518, 13521-13528, 13538-13542
424	JRB00250-00254, 337, 371, 375, 377, 382-383, 385, 387, 395-731, 733-885, 888-889, 891-931, 934
424D	CJZ00278-00292 RXA00605-02672
428D	BXC00666-02370 DSX00407-00655, 657-997 MBM00246-00328
430D	BNK06183, 6186-7307
430D IT	BML04976, 4985, 4989-5472
432D	TDR00315-00406, 410-663 WEP00789-01593, 1596, 1598-1702, 1704-1706, 1709-1712, 1714-1716, 1718-2821
442D	SMJ00222-00448 TBD00285-00351
446D	DBL00209-00691

PARTS NEEDED

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Qty	Part Number	Description
1	1145030	SPRING
6	3073178	KIT-VALVE
3	3073179	KIT-VALVE

ACTION REQUIRED

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After a spring failure, the compensator spool in the control valve must be replaced with a spool that has a wider bleed groove to adjust for the bleed slot in the body that is off location. It is recommended that all of the following control valve sections be reworked: loader-lift, tilt, auxiliary; backhoe E-stick, swing, auxiliary. See the attached Rework Procedure.

Two bore gages are required for checking the bore size so that the correct spool can be installed. The bore gages are 308-7543 and 308-7544. To aid in usage, a handle, 308-7560, and a collet, 308-7559, should be used with these gages. The cost of these gages can be claimed on the service letter. One set of gages is allowed for each dealer store servicing the included machine serial numbers.

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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%
0-4000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-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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Required Tooling

Image1.1.1

Illustration 1 - Tools for Removing and Replacing Flow Control
(A) Torque wrench 70 N?m (50 lb-ft)
(B) Breaker Bar
(C) Hammer
(D) Extension Bar
(E) Puller Tool (Dealer's choice)
(F) Bore Gauge ? 308-7543 and 308-7544 (308-7559 collet and 308-7560 handle not shown)
(G) 3/8 inch hex bit socket

Note: The puller tool (E) that is shown in Illustration 1 is a 1/4x8-inch long cap screw that has the head ground to a thickness of 0.80 inches. Any object that will enable withdrawing the spool and the spring from the valve can be used.

Repair Procedure for D-Series Backhoe Loaders

Reference: Disassembly and Assembly, RENR3585, "416D, 420D, 424D, 428D, 430D, 432D, 438D, and 442D Backhoe Loaders Machine Systems"

Note: Illustrations are for reference only. The control valve configuration on each machine may be slightly different.

1. Refer to the machine disassembly and assembly manual to gain access to the control valve and the plug that covers the flow compensator spool in the control valve.
2. Locate the control valves that are suspect for valve body bleed slot off location (Front Valve ? Loader lift, tilt, and Auxiliary; Rear Valve ? E-Stick, Auxiliary, and swing).
3. To remove the plug in the end of the control valve:
a. Install the 3/8-inch hex bit socket onto the extension bar and insert the bit into the head of the plug. Tap the extension with a hammer in order to seat the bit into the plug.

Image1.3.1

b. Assemble the breaker bar to the extension. Exert force in a counterclockwise direction in order to break the plug loose. Then, unscrew and remove the plug.

Image1.4.1

4. Insert the puller tool into the valve. Maneuver the puller tool in order to grasp the inside lip that is located on the top of the spool. Carefully withdraw the spool from the valve.

Image1.5.1

5. Reinsert the puller tool into the valve. Maneuver the puller tool inside the valve in order to grasp the spring. Withdraw the spring from the valve.

Image1.6.1

6. Carefully place the end of the #1 gauge (308-7543) into the valve opening.

Image1.7.1

7. Use a slight twisting motion and downward pressure as you attempt to insert the gauge fully. The gauge is inserted fully when the gauge is inserted to the groove that is provided on the gauge.

Image1.8.1

Image1.8.2

8. If the #1 gauge (308-7543) can be fully inserted into the valve opening, use the standard size repair kit (307-3178) for the replacement spool.
9. If the #1 gauge (308-7543) cannot be fully inserted in the valve opening, insert the #3 gauge (308-7544).
10. Use the same slight twisting motion and downward pressure as you attempt to insert the gauge fully. The gauge is inserted fully when the gauge is inserted to the groove that is provided on the gauge.
?If the #3 gauge (308-7544) can be fully inserted in the valve opening, use the undersize repair kit (307-3179) for the replacement spool.
?If the #3 gauge (308-7544) cannot be fully inserted in the valve opening, replace the control valve section.

Note: A maximum of two undersize spools can be installed on "air conditioned" machines or a maximum of three undersize spools on "non-air conditioned" machines.
?When an "air conditioned" machine has a total of three or more failed functions and the gauge fits into all of the bores, replace the complete valve stack that has the most failed functions.
?When a "non-air conditioned" machine has a total of four or more failed functions and the gauge fits into all of the bores, replace the complete valve stack that has the most failed functions.

11. Insert the new spring into the valve opening. Some control valves use a nested spring arrangement. For these control valves install the new 6E4317 Spring and a new 114-5030 Spring.

Image1.9.1

12. Carefully insert the new spool into the valve opening.

Image1.10.1

13. Exert downward force on the spool in order to seat the spool fully in the valve and to ensure that the bottom of the spool surrounds the top portion of the spring.

Image1.11.1

14. Install the new 2M-9780 O-Ring Seal on the new plug.
15. Reinstall the plug in the valve. Tighten the plug to a torque of 70 ? 7 N?m (50 ? 5 lb-ft).

Perform the steps in this procedure on each of the following control valves that are equipped on the machine being repaired:
?Backhoe valve swing, extendable stick, and auxiliary function
?Loader valve tilt, lift, and auxiliary function