PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE STACKABLE VALVE SECTION IN THE GRAPPLE ROTATE HYDRAULIC CIRCUIT ON CERTAIN 322C EXCAVATORS

Usage:

SEBE8090

August 2, 2002
U-190

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE STACKABLE VALVE SECTION IN THE GRAPPLE ROTATE HYDRAULIC CIRCUIT ON CERTAIN 322C EXCAVATORS
5481		PI10141

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10141" as the Part number and "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 "PI10141" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The stackable valve section in the grapple rotate hydraulic circuit needs to be replaced on certain 322C Excavators. The machine swing movement may speed up suddenly when the grapple rotate function is operated simultaneously. The opening of the F-4 Valve creates a negative flow control pressure thus stroking the hydraulic pump causing the speed change.

AFFECTED PRODUCT

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Model	Identification Number
322C	CBY193-196

PARTS NEEDED

1 - 2246850 Conversion Group Note: Ask your Machine Ordering desk to place an order for (1) 0P6036 (322C FM Misc. Material). Within this order, use the 2246850 Conversion Group. All parts required for the rework are in the conversion group. Order one conversion group per machine. Only machines listed in the Affected Product list are eligible for this one-time part ordering process.

ACTION REQUIRED

The F-4 valve section must be removed from the main control valve. An auxiliary pump and control valve must be added to the hydraulic system to power and control the grapple rotate hydraulic circuit. See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	16	0	0	0	0
NOTE: This is a 16-hour job.

PARTS DISPOSITION

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - The Stackable Valve Section in the Grapple Rotate Hydraulic Circuit Needs To Be Replaced

MODELS INVOLVED - 322C Excavators

Dear Caterpillar Product Owner:

The stackable valve section in the grapple rotate hydraulic circuit needs to be replaced on certain 322C Excavators. The machine swing movement may speed up suddenly when the grapple rotate function is operated simultaneously, which could result in injury or death. New valve section needs to be installed on the products listed below. 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 August 2, 2002 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 August 2, 2002 Service Letter

Rework Procedure

The Purpose for this document is to provide instructions on how to change the power source for rotating the grapple from the F4 (Flow Control Valve) to an auxiliary pump and solenoid valve. The hydraulic system should be changed using the following procedures.

1. The following is the procedure for reworking the 1619406 Control Arrangement, updating it to a 2102965 Control Arrangement for Log Loaders:

1970185 Valve Group ? Main

Remove the following components from the Main Control Valve Gp.:

5 - 7I1026 Bolt-Socket Head
1 - 1907739 Valve Group - Cont ? A
1 - 1970192 Plate - Identification

Install the following components on the Main Control Valve Gp.

1 - 2154974 Plate - Identification (See Note for special Instructions)
5 - 8T4140 Bolts

See Picture shown below

Note: New Main Control Valve Identification Plate (2154974) you need to stamp the OLD valve part number (1970185), the NEW valve part number (2154973) and the valve SEQUENCE number before installation on the valve. Contact Rex Johnsen at (630) 859-5531 with this information.

1877164 Lines Gp ? Pilot

Remove the following from this group:

1 - 6D1641 Clip

1 - 8T4121 Washer-Hard

1 - 8T4133 Nut

1 - 8T4196 Bolt

1 - 0875771 Hose As.

1 - 1488336 Connector As.

1 - 1488353 Elbow As.-45 Deg

1 - 1488378 Elbow As.-90 Deg

4 - 1488407 Plug As.-STOR

1 - 1849155 Hose As.

1877166 Lines Gp ? Pilot

Remove the following components from this group:

4 - 3J1907 Seals 1 - 4I0836 Hose As.

1 - 4I1704 Hose As. 1 - 4I1739 Hose As.

2 - 4I9522 Band-Hose 2 - 4I9525 Band-Hose

2 - 5C7261 Nut 1 - 6D4244 Clip

4 - 6V0852 Cap-Dust 4 - 6V3965 Nipple As.

4 - 7K1181 Strap-Cable 1 - 7Y4190 Hose As.

2 - 8T3647 Bolt 1 - 8T4137 Bolt

1 - 0876585 Hose As. 1 - 1049048 Hose As.

1 - 1087387 Hose As. 1 - 1087572 Hose As.

1 - 1110988 Hose As. 1 - 1232430 Valve Gp-SHTL

1 - 1319503 Hose As. 1 - 1346918 Hose As.

1 - 1488318 Connector As. 1 - 1488338 Connector As.

2 - 1488340 Connector As. 1 - 1488342 Connector As.

2 - 1488353 Elbow As.-45 Deg 1 - 1488370 Elbow As.

4 - 1488371 Elbow As. 1 - 1488374 Elbow As.-90 Deg

3 - 1488393 Elbow As. 2 - 1488411 Plug As.-STO

1 - 1488428 Tee As.-ORFS 2 - 1488435 Tee As.-ORFS

1 - 1504043 Connector As. 1 - 1504048 Elbow As.

1 - 1645629 Fitting As. 1 - 1673466 Switch As.-Press.

1 - 1734816 Support As. 1 - 1764760 Hose As.

1 - 1849208 Hose As. 1 - 1849209 Hose As.

1 - 1850497 Valve Gp-Sol 1 - 1877023 Plate

2 - 1877156 Hose As. 1 - 1926774 Hose As.

2 - 1926775 Hose As. 1 - 1940018 Support As.

1 - 1940095 Support As.

2214717 Lines Gp ? Pilot (New)

Install the following components that are shown on this group:

1 - 4I0818 Hose As. 1 - 4I1783 Hose As.

1 - 4I7889 Hose As. 2 - 4I9523 Band-Hose

2 - 4I9527 Band-Hose 1 - 5K8451 Clip

1 - 6D1641 Clip-Loop 1 - 8T4121 Washer

1 - 8T4191 Bolt 1 - 8T5005 Bolt

1 - 8T6870 Bolt 1 - 0875764 Hose As.

1 - 1105496 Hose As. 1 - 1105511 Hose As.

2 - 1335813 Band-Hose 3 - 1350207 Strap-Cable

1 - 1488336 Connector As. 1 - 1488367 Elbow As.

6 - 1488378 Elbow As.-90 Deg 1 - 1488433 Tee As.-ORFS

1 - 1503036 Elbow As. 1 - 1645549 Coupling As.

1 - 1764578 Hose As. 2 - 1797616 Hose As.

1 - 1797634 Hose As. 1 - 1907820 Valve Gp-Sol

1 - 2024006 Hose As. 1 - 2048288 Support As.

1 - 2125215 Support As. 1 - 2214807 Hose As.

1877165 Lines Gp - Front

Remove the following components from this group:

2 - 1P4577 Flange-Half 2 - 4J5267 Seal-O-Ring

2 - 6V8398 Seal-O-Ring 4 - 8T4186 Bolt

1 - 1849404 Clip 1 - 1875586 Support

1 - 1930615 Tube As. 1 - 1939616 Seal-O-Ring

1 - 1991957 Hose As.

2214716 Lines Gp ? Front (New)

Install the following components that are shown on this group:

2 - 1P4578 Flange-Half 2 - 1P4579 Flange-Half

2 - 1P4579 Flange-Half 1 - 2J2668 Cover

1 - 4J0522 Seal-O-Ring 2 - 4J0524 Seal-O-Ring

1 - 4T2958 Hose As. 1 - 4Z5913 Valve Gp-Sol&Relief

2 - 5P7464 Clip 2 - 5P7465 Clip

2 - 6D4636 Clip 3 - 6J2680 Seal-O-Ring

1 - 7I7900 Hose As. 3 - 8T2920 Grommet

4 - 8T4121 Washer 2 - 8T4176 Bolt

8 - 8T4183 Bolt 1 - 8T4192 Bolt

1 - 8T4194 Washer 4 - 8T4196 Bolt

31 - 8T4223 Washer 4 - 8T4224 Washer

13 - 8T4956 Bolt 4 - 8T6868 Bolt

2 - 0959785 Clamp-Hose 4 - 1017404 Bolt-Socket Head

1 - 1148421 Hose As. 1 - 1488328 Connector As.

5 - 1488340 Connector As. 1 - 1488364 Elbow As.

1 - 1488444 Tee As.-ORFS 1 - 1404048 Elbow As.

1 - 1536232 Elbow As. 1 - 1875833 Hose As.

1 - 1876850 Plate 1 - 1877011 Pipe As.

1 - 1960737 Hose As. 1 - 2024014 Hose As.

1 - 2133290 Adapter 1 - 2214706 Hose As.

1 - 2214805 Bracket As. 1 - 2214823 Support As.

1 - 2214825 Support As. 1 - 2214827 Bracket As.

1 - 2214831 Pipe As.

The following picture is to show the pump compartment with the valves and the lines routing. Use this As. a guide to make sure your machine looks like this.