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PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 312C, 315C, 318C, AND 319C EXCAVATORS Caterpillar


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PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 312C, 315C, 318C, AND 319C EXCAVATORS [REBE2450]
HYDRAULIC SYSTEM
LINES GP-CYLINDER
PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 312C, 315C, 318C, AND 319C EXCAVATORS
REBE2450-01

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10Sep2007
(Revised 14Sep2007)


U-438
O-385

 
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Before/After
  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 312C, 315C, 318C, AND 319C EXCAVATORS
5067 5147 5811 5051 5117
PS42505
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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 "PS42505" 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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NOTE:

This Revised Service Letter replaces the 10Sep2007 Service Letter. Changes have been made to the Title.

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TERMINATION DATE
30Sep2009

PROBLEM

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The 211-4179, 214-6222 and 214-6224 Boom Lowering Check Valves located on the boom cylinders may whistle during the boom lowering operation and need to be reworked on certain 312C, 315C, 318C and 319C Excavators.

AFFECTED PRODUCT

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Model Identification Number
*******Group  1*******
315C  ANF00164-00170, 173-176, 179-181, 184, 188-190, 192, 194, 196-198, 200-201, 203-205, 208-210, 212, 215-219, 221, 223-226, 228, 231, 233, 236, 239-241, 243-244, 249, 252, 254-256, 261, 264-267, 269-270, 273-274, 279, 281-283, 285-287, 290, 292-295, 297, 306-307, 310, 312, 315-319, 321-322, 326-332, 334-338, 340, 342-343, 346-350, 352-353, 356, 358-360, 363-367, 370-373, 376-378, 381, 383-384, 387-391, 393, 396-398, 401-406, 408-409, 411, 414-417, 419, 421-428, 430-431, 433, 435, 438, 440, 442-448, 450, 452-454, 457, 460, 463-466, 468-470, 472-481, 483, 487-498, 500, 502-505, 507, 509-510, 513-515, 517-518, 521-522, 524-525, 527-530, 532, 536, 538-540, 544-545, 550-551, 554-556, 950-992
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*******Group  2*******
312C BNN00460, 501, 510, 538-540, 567-568

CBT00787-00789, 792, 797-800, 805, 807, 810-811, 813-814, 817, 820-821, 823, 825-826, 829, 831-832, 834-836, 839, 841, 843-844, 846-847, 849-851, 857, 859, 862, 867-870, 872, 874-877, 879, 882, 890-892, 898-899, 901, 903-904, 906, 908, 910, 919, 927, 934, 937, 940

DBN00176, 180, 188, 200, 206, 220-224, 227, 232, 236-240, 263, 269, 271-272, 283, 297, 304, 307, 316, 318, 321, 335-336, 365, 380, 389, 392, 409, 414-417, 420, 423-424, 429-433, 435, 437-445, 448-450, 452-453, 455-464, 467-475, 477-479, 934-937, 939, 942-943, 948, 951, 953-954, 957, 962-965, 967-973, 975, 977, 979, 984-986, 988-995, 1001-1003
312CL  BWH00191, 193-194, 197, 200-201, 204, 209, 213, 215-217, 220-232, 234, 236, 238, 240-243, 246-247, 250, 252-256, 263, 265, 269-276, 280-283, 290, 292, 295, 300-301, 305, 308, 310-313, 321, 328-330, 337, 339, 341-342, 344-345, 347, 350-352, 354-355, 357, 359-362, 365-366, 370, 372, 375-377, 379, 381-383, 386-387, 392-396, 403-404, 406-408, 411, 413-415, 417-418, 420-421, 425, 428, 432, 436, 438, 443, 447-448, 451, 457, 462-463, 466, 470-474, 476, 478-480, 483-484, 487-488, 490, 497, 500, 508, 512, 514, 517, 521, 523-524, 526-528, 534, 536, 538, 540-542, 547-549, 551, 556-558, 566-567, 570-571, 573, 578, 582-583, 586, 588-591, 593-594, 597-598, 601-604, 608, 611-612, 614, 625, 627, 629-632, 635, 643, 646-647, 654, 665, 667-668, 680-682, 685, 687, 692, 695, 697-699, 703, 706, 708-711, 715, 720-721, 723, 731, 735-737, 740, 742-743, 748-749, 751, 756, 759, 761-762, 765, 768, 774, 777-778, 782-784, 788-797, 800-801, 803, 806-807, 809, 811-813, 816-820, 822-827, 830, 832-833, 835-836, 838, 840-841, 843-844, 849-851, 1390-1398, 1400-1404, 1406-1415, 1417-1437, 1439-1441, 1443-1445, 1448, 1450-1452, 1454-1471
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*******Group  3*******
318C BTG00149-00150, 158-172, 174, 176-178, 186, 191, 203, 206-207, 209-210, 212-213, 219, 223, 234-236, 238-240, 242-244, 247-248, 252, 258, 261, 264-265, 279

DAH00122-00134, 137, 142, 144-146, 148-151, 153, 155, 157, 159-160, 162-163, 167-168, 170-172, 174-179, 181-187, 189-200, 202, 204-205, 208, 210-216, 219, 221-223, 227-230, 232-234, 236-238, 240-245, 247-248, 250-252, 256, 258, 260-261, 264-266, 268-271, 276-277, 283-284, 290, 292, 294-295, 298-299, 301-303, 305-306, 308-315, 317-330, 338-339, 344, 346-347, 350, 354-355, 358, 360, 362-364, 367-369, 371-372, 374-378, 381-382, 384, 387-388, 392-394, 396-400, 402-406, 409-411, 420-423, 427, 429-434, 438-439, 447, 450, 458, 461, 465, 471, 475-476, 479-484, 489-490, 492-493, 495, 497-499, 501-503, 505, 510, 513, 519-520, 522, 525, 527-528, 533, 537-538, 540-542, 544, 549-553, 557-560, 562-563, 567, 571-572, 576-577, 579, 581-582, 584-588, 596-597, 603, 611-614, 618-619, 625, 627-631, 638, 640, 642, 648, 650, 653-654, 656, 659, 662-663, 665-667, 669-671, 1218-1224, 1226-1230, 1232-1240, 1243-1244, 1249-1250, 1255-1257, 1259-1261, 1263-1265, 1267-1269, 1271-1272, 1274-1278, 1280

FAA00189-00202, 204-210, 212-213, 215-221, 224, 226-227, 229-232, 238, 241-242, 246-248, 250, 252, 254, 256-262, 264-265, 267, 270-271, 274-275, 277-281, 284-285, 289-293, 295-296, 298-299, 301-309, 311-314, 316-317, 319-322, 324-326, 330-344
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*******Group  4*******
319C  KGL00188-00189, 191-192, 194, 196-201, 205-211, 213-215, 220-221, 223-224, 226-227, 230-233, 237, 239-244, 246-253, 256-257, 259, 262-279, 281, 289, 291-292, 294-298, 301, 304-306, 308-309, 311, 313, 315-316, 318-321, 324-325, 327-328, 332-333, 337, 340-345, 347, 738, 740-744, 746-785

PARTS NEEDED

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Qty

 Part Number Description
*******Group 1*******
2 4K1388 SEAL-O-RING
2 3110010 POPPET
2 3111876 VALVE
2 3111906 PLUG
2 3111912 GUIDE
*******Group 2*******
1 4J7386 SHIM
2 4K1388 SEAL-O-RING
2 3110010 POPPET
2 3111876 VALVE
2 3111906 PLUG
2 3111912 GUIDE
*******Group 3*******
2 4K1388 SEAL-O-RING
2 3110009 POPPET
2 3111876 VALVE
2 3111906 PLUG
2 3111912 GUIDE
*******Group 4*******
2 4K1388 SEAL-O-RING
2 3110009 POPPET
2 3111876 VALVE
2 3111906 PLUG
2 3111912 GUIDE

ACTION REQUIRED

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Refer to the attached Rework Procedure.
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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs,
25-48 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 1.0-hour job for Group 1

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Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs,
25-48 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 1.0-hour job for Group 2

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Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs,
25-48 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 1.0-hour job for Group 3

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Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
2001-4000 hrs,
25-48 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 1.0-hour job for Group 4



PARTS DISPOSITION

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


Rework Procedure


 
See Image 1.1.1 for an overall view of the complete rework procedure.
Image1.1.1
 
SAFETY OPERATIONS PRIOR TO 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 - See Image 1.2.1

3) Stop the engine.

4) Release the pressure in the boom down hydraulic circuit. Refer to RENR6690 Testing & Adjusting Section, "Hydraulic System Pressure - Release Of Hydraulic Pressure From A Single Hydraulic Circuit".
Image1.2.1
 
DISASSEMBLY PROCEDURE:
5) Loosen the 211-4182 Plug (item n? 15).

6) Slowly remove the 211-4182 Plug to collect the following parts:
a) 4J7386 and/or 211-7944 shims (item n?23 and/or 2). Carefully handle the exact quantity of shims which must be reused later at step 8 (the shims may remain inside the 211-4182 Plug and/or onto the face of the 211-4181 Guide (item n?14).
Note: Use a degreasing agent and a magnet pen tool to help remove the remaining shims from the plug.
b) 211-4181 Guide (item 14).
c) 211-4183 Spring (item 16). Carefully handle this spring which must be reused step at 10.
d) 211-4184 Retainer (item n?17) and 211-4185 Poppet (item n?18).
e)For Group 1 and 2 only:
211-6146 Poppet (item n?25).
For Group 3 and 4:
211-4186 Poppet(item n?25).
f) Pin part of 294-4473 Guide Assmebly (item n?19). Carefully handle the pin which must be reused at step 12.
Image1.3.1
 
ASSEMBLY PROCEDURE:
7) Install the new 4K1388 Seal-O-Ring onto the new 311-1906 Plug (replacement of item 15).

8) For Group 1, 3 and 4:
Insert all the shims formely removed (step 6) inside the new 311-1906 Plug.
For Group 2 only:
Insert all the shims formely removed (step 6) and one 4J7386 Shim inside the new 311-1906 Plug.

9) Place the new 311-1912 Guide (replacement of item 14) inside the new 311-1906 Plug.

10) Install the former 211-4183 Spring removed (step 6) onto the new 311-1912 Guide.

11) Keep this assembly for later use - See Image 1.4.1
Image1.4.1
 
12)For Group 1 and 2 only:
Place the Pin (item n?19) into the new 311-0010 Poppet and install this assembly into the valve.
For Group 3 and 4 only:
Place the Pin (item n?19) into the new 311-0009 Poppet and install this assembly into the valve.
Note: Be careful, the grooves of the pin must be oriented upward. Do not orientate the grooves on the Poppet side - See Image 1.5.1

13) For Group 1 and 2 only:
Insert the new 311-1876 Poppet inside the bore of the new 311-0010 Poppet.
For Group 3 and 4 only:
Insert the new 311-1876 Poppet inside the bore of the new 311-0009 Poppet.
Image1.5.1
 
14) Install the plug assembly obtained in step 11 into the valve.

15) Tighten the 311-1906 Plug to a torque of 190 +/- 19 Nm.

16) Repeat step 5 thru 15 for the second BLCV.

17) Start the engine.

18) 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.
 
 

Information System:

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