Usage:
December 14, 2001
(Revised January 2003)
U-345
A-243
AU-235
S-185
O-265
After failure only |
PRODUCT SUPPORT PROGRAM FOR UPDATING THE GRAPPLE AUTO-GRAB PRESSURE SWITCH TO A PRESSURE SENSOR ON CERTAIN 525B, 535B AND 545 WHEEL SKIDDERS |
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1408 5570 5057 |
PS50359
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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 Caterpillar product analyst.
NOTE: This Revised Service Letter replaces the December 14, 2001 Service Letter. Changes have been made to the Rework Procedure.
TERMINATION DATE
December 31, 2003PROBLEM
The grapple pressure switch may fail on certain 525B, 535B, and 545 Wheel Skidders. If the grapple pressure switch fails, an update to a pressure sensor for increased service life is needed. Changing to the sensor requires installation of a hose, which acts as an accumulator to protect the sensor from pressure spikes in the hydraulic system. This update also requires a software change to the grapple/transmission control, and some minor additions and changes to the Skidder wiring.AFFECTED PRODUCT
Model | Identification Number |
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525B |
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535B |
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525B |
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535B |
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545 |
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545 |
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PARTS NEEDED
1 ? 1257325 Hose
1 ? 1412940 Sensor
1 ? 1646871 Adapter
1 ? 1S0994 Clip
1 ? 2039165 Harness-As
1 ? 2076122 Wire As
1 ? 3E2337 Adapter
1 ? 3J1907 Seal-O-ring
1 ? 5P7854 Clip
4 ? 6V8397 Seal-O-ring
1 ? 6V8636 Connector-seal
2 ? 6V9850 Elbow-swivel
1 ? 8T4121 Washer-hard
1 ? 8T4136 Bolt
1 ? 9R3572 Boss (M12 X 1.75-6H THD)
***** Group 3 and 4 *****
1 ? 1087658 Hose
1 ? 1412940 Sensor
1 ? 1646871 Adapter
1 ? 1S0994 Clip
1 ? 2039165 Harness-As
1 ? 2076122 Wire As
1 ? 3E2337 Adapter
1 ? 3J1907 Seal-O-ring
1 ? 5P7854 Clip
5 ? 6V8397 Seal-O-ring
1 ? 6V8636 Connector-seal
2 ? 6V9850 Elbow-swivel
1 ? 8T4121 Washer-hard
1 ? 8T4136 Bolt
1 ? 8C8988 Elbow
1 ? 9R3572 Boss (M12 X 1.75-6H THD)
ACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first | Caterpillar | Dealer Suggested | Customer Suggested | |||
Parts | Labor Hrs | Parts | Labor Hrs | Parts | Labor Hrs | |
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0-2500
/ 0-24 months |
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2501-3500
/ 25-36 months |
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NOTE: This is a 6.5?hour job. | ||||||
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0-2500
/ 0-24 months |
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2501-3500
/ 25-36 months |
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Note: This is a 4.5-hour job. |
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.Attach. (1-Rework Procedure)
Rework Procedure
Illustration 1
525B/535B Switch Location
Illustration 2
545 Switch Location
- Remove the grapple control valve guard.
- Remove the winch guards (if equipped with a winch).
- Remove the fuel tank guard (if not equipped with a winch). Removing these guards will be necessary in order to route the hose and wire harness from the grapple control valve area to the hitch area.
- Remove the auto-grab pressure switch from the hydraulic tube.
- Install the hose and route to the center hitch area (Refer to Illustration 3).
- Install 2039165 Harness. Connect the single wire connector to the four-pin connector on the rear harness (normally used for the swing grapple).
- Connect the two-pin connector to the two-pin connector that was connected to the pressure switch. On the 525B and 535B switch the yellow and black wires in this two pin connector so that they match up with the yellow and black wires on the new 2039165 Harness. (These wires should not need to be switched on the 545).
- Attach the pressure sensor to the hose.
- Weld the 9R3572 Boss in the general location shown in illustration 5 and 6 depending on the model of Skidder.
- Connect the three-pin connector of the 2039165 Harness to the new pressure sensor (Illustration 5 & 6).
- Attach the sensor to the 9R3572 Boss.
- Secure wires where possible to prevent movement with tie wraps.
- Remove the sheet metal located at the rear of the cab to gain access to the Grapple/Transmission electronic controller.
- Move circuit E852 YL from J-1 connector pin 36 of the Grapple/Transmission control to J-2 connector pin 38 of the Grapple/Transmission control.
- At the grapple handle there are two unused two pin plugs on the harness. Plug them together by installing the 2076122 Wire Assembly (refer to Illustration 7) to get power to the rear. (This will connect circuit 165 YL to K934 GN. This will mean that the fuse operating this circuit is labeled DIFF LOCK-10A.)
- Flash the Skidder with 231-3867 Flash File.
- Perform the torque converter lock-up clutch calibration procedure. For more information on calibrating the torque converter lock-up clutch, refer to the power train testing and adjusting manual for the model of skidder being serviced.
- Perform the auto-grab pressure sensor calibration procedure. For more information on calibrating the auto-grab pressure sensor, refer to Service Magazine; Media Number ? SEPD0663, Publication Date ? 2003/01/20, "New Software Provides Improvements and Enhancements". In the future, information on calibrating the auto-grab pressure sensor will also be available in the grapple testing and adjusting manual for the machine that is being serviced.
Illustration 3
Example is 545 with no winch
Note:
There have been a few incidents where the black and yellow wires were reversed at the power train control module. If the auto-grab system fails to operate after performing this procedure, try reversing the yellow and black wires.
Illustration 5 (545)
Illustration 6 (525B and 535B)
Illustration 7
Software versions prior to 231-3867 did not have the feature of calibrating the auto-grab pressure control. The auto-grab system will work if the pressure sensor is not calibrated but there will be a fault code of 455-13. The auto-grab pressure sensor should be calibrated to better match the pressure setting of the hydraulic pump.