Usage:
NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1260" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI1260" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
NOTE: This Program supersedes the March 27, 1994 Service Letter - PI1207, which was canceled.
Problem
A new flow switch and/or tube assembly needs to be installed on certain D25D, D30D, D40D, D350D, and D400D Articulated Trucks. The flow switch is used for the category three EMS warning. The pipe assembly that may not function properly connects the supplemental steering valve to the hydraulic pump.
Affected Product
Model & Identification Number
Group 1
D25D (1HK54, 1HK60, 1HK78, 1HK82, 1HK88, 1HK101, 1HK105, 1HK120, 1HK185, 1HK186, 1HK200-203, 1HK258-261)
D30D (3AJ49, 3AJ87, 3AJ88, 3AJ103, 3AJ159, 3AJ193, 3AJ208, 3AJ219, 3AJ252, 3AJ253, 3AJ258, 3AJ272, 3AJ273 1PK1-34 )
D350D (9RF85, 9RF94, 9RF95, 9RF98, 9RF99, 9RF185-188, 9RF192, 9RF196, 9RF201-205, 9RF232, 9RF283, 9RF287, 9RF290, 9RF291, 9RF305, 9RF309, 9RF312, 9RF314, 9RF322)
D40D (2JJ1-74, 2JJ77-82, 2JJ84, 2JJ85, 2JJ87)
D400D (8TF1-37, 8TF39-50, 8TF52-185, 8TF187-189, 8TF191-207, 8TF209-311, 8TF314-333, 8TF335-358, 8TF361-402, 8TF405-420, 8TF422, 8TF423, 8TF426-432, 8TF434-439, 8TF457-462 4EJ1-20 )
Group 2
D25D (1HK243, 1HK269, 1HK270, 1HK279-283, 1HK285-299, 1HK301-306, 1HK313-421, 1HK424, 1HK425, 1HK427, 1HK429)
D30D (3AJ221, 3AJ222, 3AJ226-228, 3AJ230-232, 3AJ237, 3AJ255-257, 3AJ259-271, 3AJ286-289, 3AJ300, 3AJ302-310, 3AJ312-315, 3AJ322, 3AJ325, 3AJ327)
D350D (9RF375, 9RF377, 9RF387-390, 9RF393, 9RF400-409, 9RF415-419, 9RF423, 9RF424, 9RF426-428, 9RF430-434, 9RF437-447, 9RF450-454, 9RF456-459, 9RF462-484, 9RF486-495, 9RF502, 9RF513)
D40D (2JJ83, 2JJ86, 2JJ88-96, 2JJ99)
D400D (8TF421, 8TF424, 8TF425, 8TF433, 8TF450-456, 8TF463-495, 8TF497-505, 8TF507, 8TF510-515, 8TF517, 8TF518, 8TF521-545, 8TF547-577, 8TF580, 8TF581, 8TF584-597, 8TF600, 8TF601, 8TF603, 8TF605-622, 8TF624-631, 8TF633-663, 8TF665, 8TF667, 8TF669-672, 8TF675, 8TF676, 8TF678, 8TF679, 8TF681-685, 8TF689-695, 8TF698-711, 8TF713-725, 8TF727-748, 8TF754-760, 8TF762-774, 8TF776, 8TF789-791)
Group 3
D25D (1HK1-53, 1HK55-59, 1HK61-76, 1HK79-81, 1HK83-87, 1HK90-100, 1HK102-104, 1HK106-117, 1HK119, 1HK121-181, 1HK183, 1HK184, 1HK187-189, 1HK191-198, 1HK204-215, 1HK218-227, 1HK229-241, 1HK244-252, 1HK254, 1HK255, 1HK257, 1HK262-264, 1HK300)
D30D (3AJ1-48, 3AJ50, 3AJ51, 3AJ53-86, 3AJ89-102, 3AJ104-158, 3AJ160-192, 3AJ194-207, 3AJ209-218, 3AJ220, 3AJ233-236, 3AJ238-251, 3AJ254, 3AJ274-281, 3AJ291, 3AJ292, 3AJ301)
D350D (9RF1-84, 9RF86-93, 9RF96, 9RF97, 9RF100-184, 9RF189-191, 9RF193-195, 9RF197-200, 9RF206-210, 9RF212-227, 9RF229-231, 9RF233-286, 9RF288, 9RF289, 9RF292-304, 9RF306-308, 9RF313, 9RF315, 9RF318, 9RF321, 9RF323-372, 9RF376, 9RF379-385, 9RF391, 9RF392, 9RF394-399, 9RF410-414, 9RF425, 9RF435, 9RF436)
Group 4
D25D (1HK253, 1HK256, 1HK265-268, 1HK271-278, 1HK307-312)
D30D (3AJ223-225, 3AJ229, 3AJ290, 3AJ293, 3AJ295-299)
D350D (9RF319, 9RF320, 9RF373, 9RF374, 9RF420-422, 9RF429, 9RF460)
Group 5
D25D (1HK77, 1HK89, 1HK118, 1HK182, 1HK190, 1HK199, 1HK216, 1HK217, 1HK228, 1HK242)
D30D (3AJ52, 3AJ285, 3AJ294)
D350D (9RF211, 9RF228)
Parts Needed
Dealers will need to order parts for this Program.
Group 1
- 4 - 7X0313 Bolt
- 2 - 4J0522 Seal-O-Ring
- 1 - 3K0360 Seal-O-Ring
- 1 - 2U8088 Film
- 1 - 1184976 Harness Assembly
- 1 - 2U8941 Harness Assembly
- 1 - 2U9421 Flange
- 1 - 1094215 Switch Assembly
- 2 - 4J0522 Seal-O-Ring
Group 2
- 1 - 1094215 Switch Assembly
Group 3
- 4 - 7X0313 Bolt
- 2 - 4J0522 Seal-O-Ring
- 2 - 4J0522 Seal-O-Ring
- 1 - 3K0360 Seal-O-Ring
- 1 - 5P7470 Clamp
- 1 - 5P7471 Clamp
- 1 - 5P8182 Grommet
- 2 - 8T4223 Washer
- 1 - 8T4835 Bolt
- 2 - 8T8917 Bolt
- 1 - 2U6156 Hose Assembly* (XT3 - Fabricate)
- or
- 2U6157 Hose Assembly* (XT3 - Fabricate)
- 1 - 2U8088 Film
- 1 - 1184976 Harness Assembly
- 1 - 2U8941 Harness Assembly
- 1 - 2U9421 Flange
- 1 - 6V8188 Nut
- 1 - 1094215 Switch Assembly
- 1 - ------ Fabricated Bracket**
- 2 - 4J0522 Seal-O-Ring
Group 4
- 2 - 4J0522 Seal-O-Ring
- 1 - 5P7470 Clamp
- 1 - 5P7471 Clamp
- 1 - 5P8182 Grommet
- 2 - 8T4223 Washer
- 1 - 8T4835 Bolt
- 2 - 8T8917 Bolt
- 1 - 2U6156 Hose Assembly* (XT3 - Fabricate)
- or
- 2U6157 Hose Assembly* (XT3 - Fabricate)
- 1 - 6V8188 Nut
- 1 - 1094215 Switch Assembly
- 1 - ------ Fabricated Bracket**
- 1 - 5P7470 Clamp
Group 5
- 2 - 4J0522 Seal-O-Ring
- 1 - 5P7470 Clamp
- 1 - 5P7471 Clamp
- 1 - 5P8182 Grommet
- 2 - 8T4223 Washer
- 1 - 8T4835 Bolt
- 2 - 8T8917 Bolt
- 1 - 2U6156 Hose Assembly* (XT3 - Fabricate)
- or
- 2U6157 Hose Assembly* (XT3 - Fabricate)
- 1 - 6V8188 Nut
- 1 - ------ Fabricated Bracket**
- 1 - 5P7470 Clamp
*Use as required, the 2U6156 Hose Assembly is needed for D30D and D350D Articulated Trucks.It is also used on D25D Articulated Trucks equipped with a retarder.The retarder is an attachment on D25D Articulated Trucks.D25D Articulated Trucks without a retarder require a 2U6157 Hose Assembly
**This bracket can be fabricated locally using the dimensions given in Illustration 1. Use 6 mm (.25") mild steel plate to fabricate the bracket.
Action Required
- Group 1 - See Rework Procedure Part 1.
- Group 2 - See Rework Procedure Part 2.
- Group 3 - See Rework Procedure Parts 1 and 3.
- Group 4 - See Rework Procedure Parts 2 and 3.
- Group 5 - See Rework Procedure Part 3.
- Group 2 - See Rework Procedure Part 2.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Group 1
NOTE: This is a 2-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.
Group 2
NOTE: This is a .5-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.
Group 3
NOTE: This is a 4-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.
Group 4
NOTE: This is a 2.5-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.
Group 5
NOTE: This is a 2-hour job.
NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.
- (1-Owner Notification)
- (2-Rework Procedure)
Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Part 1 - (Affected Product Groups 1 and 3)
1. Install flange (5) as shown in Illustration 1. Use the two new O-rings (4) and longer bolts (3).
2. Screw switch (2) into the port provided using O-ring seal (1). The arrow on the switch must point in the direction of flow as shown in Illustration 1.
3. Locate and disconnect the plug in the EMS panel as shown in Illustration 2. Feed harness (6) into the dash as shown. Remove the BK-201 wire from socket number 17 and replace it with the 417-GY wire of harness (6). Splice the BK-201 wire to the BK-201 wire of harness (6). Tape the joint and install the plug.
4. Route harness (6) along the length of the existing main cab harness. Fasten/secure it in place with plastic tie wraps or tape. Connect harness (6) to switch (2) with harness (7). Secure harness (7) in a way which avoids rubbing against any sharp edges.
5. Replace the existing 7U3798 Film on the EMS panel with Film (8).
6. Test the EMS using the procedure described in the Operation and Maintenance Manual. Make all necessary checks and adjustments before returning to service.
Part 2 - (Affected Product Groups 2 and 4)
1. Replace the existing switch with a new switch (2) in the port as shown. Use a new O-ring seal (1) if required. The arrow on the switch must point in the direction of flow as shown in Illustration 1.
Illustration 1
Illustration 2
Part 3 - (Affected Product Groups 3, 4, and 5)
1. Fabricate a 2U6156 Hose Assembly for D30D and D350D Articulated Trucks and for D25D Articulated Trucks equipped with a retarder. Fabricate a 2U6157 Hose Assembly for D25D Articulated Trucks that are not equipped with a retarder. The retarder is an attachment on D25D Articulated Trucks.
2. Fabricate a bracket as shown in Illustration 3. Use 6 mm (.25") mild steel plate to fabricate the bracket.
3. Remove the existing tube assembly and hose. Install the new parts as shown in Illustration 4. Relocate the breather for the front axle to the bracket as shown.
Illustration 3
Illustration 4