PRODUCT SUPPORT PROGRAM FOR REWORKING NOISY BOOM LOWERING CHECK VALVES AND STICK LOWERING CHECK VALVES (IF INSTALLED) ON CERTAIN 312D, 315D, AND 319D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING NOISY BOOM LOWERING CHECK VALVES AND STICK LOWERING CHECK VALVES (IF INSTALLED) ON CERTAIN 312D, 315D, AND 319D EXCAVATORS [REBE4879]

HYDRAULIC SYSTEM

VALVE GP-LOAD CONTROL

PRODUCT SUPPORT PROGRAM FOR REWORKING NOISY BOOM LOWERING CHECK VALVES AND STICK LOWERING CHECK VALVES (IF INSTALLED) ON CERTAIN 312D, 315D, AND 319D EXCAVATORS

REBE4879-00

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13Apr2009

U-143

A-125

O-125

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING NOISY BOOM LOWERING CHECK VALVES AND STICK LOWERING CHECK VALVES (IF INSTALLED) ON CERTAIN 312D, 315D, AND 319D EXCAVATORS
5067 5117 5811		PS42912

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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 "PS42912" 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

30Apr2011

PROBLEM

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The noisy boom lowering check valves (BLCVs) and stick lowering check valves (SLCVs) need to be reworked on certain 312D, 315D, and 319D Excavators. Changing the small poppet will eliminate the noise during certain applications.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
312D	HJX00247-00248, 250-252, 255
312D LC	KCD00256-00259, 261, 263-264, 266-299, 301-302, 304-306, 318-322, 326, 330, 332, 334, 339-340
315D LC	NCM00187-00190, 193-194, 196, 198, 201, 205, 207-208
319D LC	BZH00154-00159, 163-166, 168-171, 173-177, 180-183, 185, 187-189, 192-201, 204-206, 208-211, 213, 215, 217-219, 221, 226-227, 230, 232-233, 235, 237, 239-240, 247, 249-252, 254, 258-262, 264-265, 269-271, 273-275, 277-282, 284-285, 287-289, 291, 294-295, 297-303, 322-324, 327-329, 335, 337-340, 342, 344-347, 349-353, 358-359, 368, 384, 386, 390, 392, 394, 410-411, 414-415, 417, 423-424, 427
319D LN	DAY00169-00171, 174-175, 177-181, 184-187, 189-198, 200-207, 209-212, 214-225, 227-239, 241-244, 249

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*****Group 2*****
312D LC	KCD00255, 260, 265, 325
315D LC	NCM00191, 203-204, 206, 209-210
319D LC	BZH00162, 184, 186, 190-191, 202-203, 207, 212, 214, 216, 220, 222-225, 228-229, 231, 234, 236, 238, 241-246, 248, 253, 256-257, 263, 266-268, 272, 276, 290, 296, 330, 354, 360, 362
319D LN	DAY00176, 199, 208, 213, 226, 240

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	4K1388	SEAL-O-RING
2	3433027	VALVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
3	4K1388	SEAL-O-RING
3	3433027	VALVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

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
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-1000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-2000 hrs, 13-24 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
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-1000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-2000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 1.5-hour job for Group 2

PARTS DISPOSITION

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

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. Refer to Image 1.1.1.
3) Stop the engine.
4) Release the pressure in the boom down hydraulic circuit and also in stick circuit if machine is equipped with a SLCV. Refer to Testing and Adjusting Manual, RENR9737, "Hydraulic System Pressure - Release".

Image1.1.1

DISASSEMBLY PROCEDURE:

NOTE: Refer to Image 1.2.1 for Item locations.

5) Loosen the 311-1906 Plug (Item 25).
6) Slowly remove the 311-1906 Plug to collect the following parts:
a) 4J-7386 and/or 211-7944 Shims (Items 16 and/or 2). Carefully handle the exact quantity of shims which must be reused later at Step 8 (the shims may remain inside the 311-1906 Plug and/or onto the face of the 311-1912 Guide (Item 26).
b) 311-1912 Guide (Item 26)
c) 211-4183 Spring (Item 13) - Carefully handle this spring which must be reused at Step 10.
d) 311-1876 Valve (Item 24)
e) Main Poppet (Item 27)
f) Pin part of 294-4473 Guide Assembly (Item 21). Carefully handle the pin which must be reused at Step 9.

Image1.2.1

Image1.2.2

Image1.2.3

ASSEMBLY PROCEDURE:
7) Replace the 4K-1388 Seal-O-Ring (Item 36) by the same part number onto the 311-1906 Plug (Item 25).
8) Insert all the shims, formerly removed in Step 6, inside the 311-1906 Plug (Item 25).
9) Place the 311-1912 Guide (Item 26) inside the 311-1906 Plug (Item 25).
10) Install the 211-4183 Spring (Item 13), that was removed in Step 6, onto the 311-1912 Guide (Item 21).
11) Keep this assembly for later use.
12) Insert the new 343-3027 Valve (Item 24) inside the bore of the main poppet (Item 27).

Image1.3.1

13) Install the plug assembly obtained in Step 11 into the valve.
14) Tighten the 311-1906 Plug (Item 25) to a torque of 190 +/- 19 Nm.
15) Repeat Step 5 through 15 for the second BLCV and for the SLCV if equipped.
16) Start the engine.
17) Slowly move the joystick to raise the boom (and the stick if equipped with SLCV) 1 meter off the ground and then lower it back down again. Repeat this operation 10 times to purge the air.