PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 312C, 315C, 318C, AND 319C EXCAVATORS
Usage:
REBE2255-00
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| 16Aug2007 |
O-359
U-406
D-334
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| Safety Parts stock action needed | PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES ON CERTAIN 312C, 315C, 318C, AND 319C EXCAVATORS |
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| 5147 5811 5117 | PI10619 |
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| NOTE: | This Program must be administered as soon as possible.
When reporting the repair, use "PI10619" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim
Description Code and "T" as the SIMS Description Code.
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PROBLEM
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| The 211-4179, 214-6222 and 214-6224 Boom Lowering Check Valves (BLCV) located on the boom cylinders need to be reworked on certain 312C, 315C, 318C and 319C Excavators. In case of failure of the return hose between the BLCV and the main control valve, some BLCVs may have a closure time that exceeds the maximum value allowed in the ISO 8643 regulation which may cause personal injury or death. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| 315C | ANF00171-00172, 178, 183, 185-186, 195, 211, 220, 222, 227, 229, 234, 238, 245, 250-251, 258, 277, 284, 288, 313-314, 320, 333, 339, 341, 344-345, 355, 357, 361-362, 369, 374-375, 379-380, 392, 394, 399-400, 407, 410, 412, 420, 429, 432, 434, 439, 441, 451, 456, 459, 461-462, 467, 482, 484, 499, 501, 506, 508, 511-512, 516, 520, 523, 531, 535, 537, 541-543, 546-549, 552-553, 557-563, 750-758, 761-776, 778-785, 788-792, 794-795, 797-807, 809-822, 824-896, 898, 900-906, 908-921, 923-926, 928-931, 934-935, 937-949 |
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| *******Group 2******* | |
| 312C | CBT00794, 827, 830, 838, 852, 854, 856, 858, 860, 871, 884, 887, 900, 902, 909, 915, 928-929, 931 DBN00228, 235, 407, 418-419, 421-422, 425-428, 434, 446-447, 451, 454, 465-466, 476, 480-481, 484-497, 499-508, 700-702, 706-718, 721-781, 785-790, 793-798, 802, 811-812, 815, 823-830, 833-834, 848-852, 855-859, 868, 870, 872-873, 877, 881, 886, 888, 890, 892, 895, 898-899, 901, 904, 910, 912-913, 917-919, 924-926, 928 |
| 312CL | BWH00195-00196, 199, 205, 210-211, 214, 218-219, 233, 249, 251, 268, 291, 293-294, 302-304, 307, 309, 317, 340, 346, 348-349, 353, 356, 367, 378, 380, 384-385, 397-399, 412, 422-424, 426, 429-431, 434-435, 442, 445-446, 455-456, 465, 467, 477, 491-492, 504, 511, 525, 532-533, 550, 553, 555, 569, 574, 584-585, 587, 595, 599, 605-607, 609, 616-617, 623-624, 628, 633, 636-637, 640-642, 644-645, 649-650, 656, 666, 669, 675-679, 686, 688-689, 693-694, 701-702, 705, 707, 712-714, 716-719, 722, 724-726, 729-730, 732-734, 741, 746-747, 750, 752-755, 757, 760, 763-764, 766-767, 770-773, 776, 786-787, 798-799, 808, 810, 821, 828-829, 831, 834, 837, 839, 842, 845-848, 852-866, 871-877, 879-887, 889-899, 901-916, 1050-1052, 1054-1057, 1061, 1063-1069, 1071-1092, 1094, 1096-1101, 1103-1110, 1112-1115, 1118-1120, 1122-1124, 1127-1128, 1130-1136, 1139-1152, 1155, 1157, 1159-1162, 1164-1184, 1186-1211, 1213-1223, 1225-1240, 1244-1259, 1261-1277, 1279-1283, 1286-1304, 1306-1333, 1335-1354, 1356-1361, 1363-1389 |
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| *******Group 3******* | |
| 318C | BTG00173, 175, 182-183, 185, 218, 220-221, 227, 233, 237, 245, 249, 253, 255, 262, 266, 275-278, 281, 284-286, 290-291, 451, 459-464, 466-468, 470-472, 475, 477, 481-482 DAH00135-00136, 138-139, 141, 152, 154, 165, 188, 207, 209, 217-218, 220, 231, 235, 246, 249, 253, 263, 267, 272-275, 281-282, 285, 293, 296, 300, 307, 331-333, 335-337, 342-343, 349, 351-353, 356-357, 359, 361, 365-366, 370, 373, 379-380, 383, 386, 391, 395, 401, 412, 414-417, 424, 436-437, 443, 451-454, 456, 460, 467, 472, 474, 477, 485, 487, 494, 508-509, 511-512, 516-517, 521, 523-524, 526, 529-532, 534-536, 539, 543, 548, 554-556, 561, 568-570, 573-575, 578, 580, 583, 593-595, 598-602, 609, 620-621, 624, 637, 639, 641, 644-647, 649, 651-652, 658, 660-661, 664, 668, 674-678, 680-686, 688-697, 699, 701, 703, 705, 707-709, 712, 720-724, 865, 867, 881-883, 886-887, 895, 897, 900, 915, 932-936, 941-954, 961-964, 967-971, 974-989, 991, 993-996, 999-1008, 1010-1016, 1018-1019, 1021, 1023-1028, 1030, 1032, 1035, 1038, 1040, 1042-1043, 1046-1054, 1059-1065, 1068-1069, 1071-1072, 1075-1079, 1081-1084, 1086-1087, 1089-1093, 1097, 1100, 1104-1107, 1109, 1112, 1116-1117, 1119, 1121, 1123, 1128, 1132-1133, 1138-1139, 1141-1151, 1153, 1157-1159, 1162-1163, 1165, 1167-1169, 1171-1172, 1174-1178, 1180-1185, 1187-1203, 1206-1208, 1210-1213, 1215-1216 FAA00203, 225, 233-234, 243-244, 272, 297, 300, 310, 315, 318, 328-329 |
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| *******Group 4******* | |
| 319C | KGL00186-00187, 190, 193, 195, 202, 204, 212, 216-219, 222, 225, 228-229, 234-236, 238, 245, 255, 258, 260-261, 280, 282-284, 288, 290, 293, 299-300, 303, 307, 310, 312, 317, 322, 326, 329-331, 334-336, 338-339, 346, 348-356, 358-359, 361-362, 364-366, 368-372, 550-555, 560, 563, 565, 567-569, 573, 575, 577-578, 580, 582, 585, 589-593, 595-648, 650-651, 653, 659-663, 667-668, 670-681, 684-685, 687-695, 697-708, 710-714, 716-720, 722-731, 733-737 |
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******* | ||
| 2 | 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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Rework all 211-4179, 214-6222 and 214-6224 Boom Lowering Check Valves from dealer parts stock as described in the attached Rework Procedure. |
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| Refer to the attached Rework Procedure. |
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OWNER NOTIFICATION
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| U.S. and Canadian owners will receive the attached Owner Notification. |
SERVICE CLAIM ALLOWANCES
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|
Submit one claim for all parts reworked from dealer parts stock. |
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| NOTE: This is a 1.0-hour job for Group 1 | |||||
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| NOTE: This is a 1.0-hour job for Group 2 | |||||
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| NOTE: This is a 1.0-hour job for Group 3 | |||||
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| NOTE: This is a 1.0-hour job for Group 4 | |||||
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE BOOM LOWERING CHECK VALVES MODELS INVOLVED - 312C, 315C, 318C, AND 319C EXCAVATORS Dear Caterpillar Product Owner: The Boom Lowering Check Valves need to be reworked on the products listed below. In case of failure of the return hose between the BLCV and the main control valve, some BLCVs may have a closure time that exceeds the maximum value allowed in the ISO 8643 regulation which may cause personal injury or death. You will not be charged for the service performed. Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated 16Aug2007 when scheduling this service. We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction. Caterpillar Inc. Identification #(s) Attached to 16Aug2007 Service Letter |
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| See Image 1.1.1 for an overall view of the complete rework procedure. |
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| 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". |
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| 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. |
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| 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 |
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| 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. |
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| 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. |
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