PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 140M AND 160M MOTOR GRADERS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 140M AND 160M MOTOR GRADERS

Usage:

REBE6394-01

07Oct2010
(Revised 10Jan2011)


U-414
A-330
D-355
O-359

 
Safety
  
 Parts stock action needed 

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 140M AND 160M MOTOR GRADERS

7610 7620 7601 7332 4307 5051 1130 1902
PI10823
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10823" 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 "PI10823" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.

 
NOTE:

This Revised Service Letter replaces the 07Oct2010 Service Letter. Changes have been made to the Action Required to provide additional information regarding the resolver in the Actuator Valve Group (Steering Control Module) as well as an additional note regarding engine software for certain 140M Motor Graders.



PROBLEM

The Ripper handle switch/switches need to be replaced on certain 140M and 160M Motor Graders. The existing switch may fail causing uncommanded movement of the ripper or auxiliary function.
The Valve Gp-Actuator (Primary Steering Control Module) needs to be inspected on certain 140M and 160M Motor Graders. The existing Valve Gp-Actuator may cause excessive steering system codes to be generated.
The Park Brake Solenoid needs to be replaced on certain 140M and 160M Motor Graders. The existing Park Brake Solenoid may experience a failure that can prevent it from actuating.

The above failures, in conjunction with other factors or circumstances, could result in a risk of personal injury or death.

New software needs to be installed on certain 140M and 160M Motor Graders.
Software improvements are listed below.

Messenger:
-Update E875 "Low System Voltage" from a level 3 to a level 2 event
-Updated languages
-Update to reduce the frequency of 811-09 diagnostic codes at machine startup.
-Addition of an E490-1 "Park Brake Applied While Shift Lever Not in Neutral" event
-Addition of an E562-2 ?Steering Lever Has Not Been Aligned To Wheel Steering Angle? Event.

Implement:
-Reduced the debounce time for the Neutral Articulation switch from 100ms to 50ms to allow the selection to made easier.
-Alignment of the Left Hand Joystick to the steering axle when the machine is started has been improved.
-The display for Steering Oil Temperature will no longer display **** when the temperature of the steering oil is above 60 deg C or below -50 deg C.
-Remove invalid 2202-12 "Primary Steering Control Module Failure" at machine start up.
-When an E256-3 "Steering in the Wrong Direction" or an E257-3 "Steering With No -Command" occurs while in secondary steering (Trans/Chassis ECM), the secondary steering hydraulic valves will remain active.
-Correct issue with configuring cylinder trim file parameters manually through Cat ET.
-Revised the hydraulic oil viscosity parameters for Hydraulic Cold Mode that trigger the Level 1 and Level 2 "Gear Too High" events.

Transmission:
-Improved Park Brake release strategy to eliminate the possibility of driving through the park brake when the machine is put into gear. The change makes it necessary to have the park brake switch disengaged in order for the transmission to be shifted out of NEUTRAL.
-Increased the maximum detectable Transmission Output Speed from 5000 rpm to 7000 rpm (Maximum ground speed detected will now peak at 89 kph or 55 mph).
-A software change has been made to address a hesitation in machine direction change after the operator executes a directional shift while in Autoshift mode. The previous software did not allow directional shifts to execute while a downshift is in-progress.
-Update 5F to 6F and 6F to 5F shifts to provide a more aggressive shift

Engine:
-Throttle lock will be disabled when cycling the throttle lock switch from manual to auto and from auto to manual.
-Revised the E172-1 "High Air Filter Restriction" trip level from 6.5 kPa to 7.5 kPa at 15 seconds to correct an issue that causes the air filter restriction light to activate prematurely.
-Revised the E172-2 "High Air Filter Restriction" trip level from 6.5 kPa to 7.5 kPa at 30 seconds to correct an issue that causes the air filter restriction light to activate prematurely.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
140M B9D02269, 2276-2282, 2523-2525, 2527-2562, 2564-2583, 2585-2597, 2599-2602, 2604-2663, 2665-2668, 2670-2738, 2740-2744, 2751-2762, 2765-2787, 2789-2791, 2793-2794, 2797-2800, 2802-2830, 2833-2834, 2836-2838, 2840, 2849-2851, 2854-2899, 2901-2902, 2904-2906, 2911

B9G01016-01019

B9M00959-00973, 975-988

D9G01039-01094, 1096-1119, 1121, 1123-1124
160M B9E00427-00481, 485-487

B9L00486-00492

B9T00165-00167

D9T00138-00155
*******Group  2*******
140M B9D00249, 251-252, 256-257, 264, 266, 270-271, 295, 393, 444, 455, 492-494, 498-499, 504, 535, 549, 555, 577, 593, 610-611, 623, 631, 642-643, 645, 706-707, 712, 722, 724, 743, 751, 762, 787-788, 790-791, 793, 800-801, 861, 873, 879-882, 889, 896-897, 900, 903, 905, 907, 914, 919-921, 927, 939, 947, 1007-1010, 1017, 1040, 1042, 1053, 1056-1057, 1059, 1062, 1064, 1070, 1074, 1078, 1097, 1099, 1107, 1161, 1164, 1167, 1174, 1184, 1234, 1240, 1245, 1249, 1253, 1290, 1308, 1310-1312, 1364-1365, 1370, 1377, 1383, 1388-1389, 1392, 1400, 1408, 1411-1412, 1418, 1463, 1467, 1480, 1483-1484, 1488, 1491, 1550-1551, 1706, 1772-1773, 1777-1778, 1786-1787, 1790, 1792-1793, 1816, 1836-1837, 1840, 1842-1846, 1849, 1851-1852, 1855-1858, 1865, 1867, 1870, 1881, 1930-1932, 1936, 1948, 1950, 1952, 1956-1957, 1959, 1965-1966, 1973, 1977, 1987, 1990, 1993

B9G00167, 172, 174, 176-177, 190-191

B9M00166, 180, 184, 225, 249, 258, 275, 279-280, 287, 306, 343, 359, 362-363, 367, 399, 402-403, 412, 416, 419, 421, 425-426, 452, 480-481, 503, 569, 571, 596-598, 752, 802

D9G00100, 102, 105, 112, 114, 133, 137, 142-143, 146-147, 149-151, 160, 170-171, 177
160M B9E00117, 144, 146, 204, 206, 217, 228-233, 235-238, 242-243, 245-248, 252-254, 257-268, 271

B9L00165, 220-221, 270-271, 285, 287, 297

B9T00117-00118, 121, 125-126

D9T00102, 105, 108, 118
*******Group  3*******
140M B9D00137, 171, 185, 188, 325-326, 332-334, 379-380, 456, 471-473, 520, 536, 539, 542-543, 545-548, 580, 715, 719, 765, 859-860, 867, 874-875, 883-884, 886, 895, 989-991, 1068, 1108-1109, 1215, 1231, 1441, 1630, 1878-1879, 1922, 1954, 1958, 1976, 1981

B9G00104, 110, 188

B9M00148, 150, 208, 215, 218, 224, 229, 232, 353, 374, 376, 393, 407, 410, 413, 450, 454, 458, 463, 475, 479, 531, 535, 538, 556, 586, 590-591, 595, 606-607, 661, 665-668, 691, 702, 706

D9G00164-00165
160M  B9L00178, 360, 363
*******Group  4*******
140M B9D00130-00132, 134, 138-145, 149-150, 152-170, 172-184, 186-187, 189-223, 225-236, 238-241, 243-248, 250, 253-255, 258, 262, 267-269, 272-294, 296-298, 300-324, 327-328, 338-378, 381-392, 394-443, 445-454, 457-470, 474-488, 491, 497, 500-503, 507-519, 521-534, 537-538, 540-541, 544, 550-554, 556-576, 578-579, 581-592, 594-609, 612-622, 624-630, 632-633, 635-641, 644, 646-705, 708-711, 713-714, 716-718, 720-721, 723, 725-742, 744-750, 752-761, 764, 766-786, 789, 792, 794-799, 802-858, 862-866, 869-872, 876, 878, 885, 887-888, 890-894, 898-899, 901-902, 904, 908-913, 915-918, 922-926, 928-938, 941-946, 948-951, 953-988, 992-1006, 1011-1016, 1018-1039, 1041, 1043-1052, 1054-1055, 1058, 1060-1061, 1063, 1065-1066, 1069, 1072-1073, 1075-1077, 1079-1096, 1098, 1100-1106, 1110-1160, 1162-1163, 1166, 1168, 1170-1171, 1173, 1176-1179, 1181-1183, 1186-1189, 1191-1193, 1195-1198, 1200-1204, 1207, 1209-1214, 1216-1228, 1230, 1232-1233, 1235-1239, 1241-1244, 1246-1248, 1250-1252, 1254-1289, 1291-1307, 1309, 1313-1343, 1345-1348, 1350-1355, 1357-1363, 1366-1369, 1372-1375, 1378-1382, 1384-1387, 1390-1391, 1393-1399, 1401-1407, 1409-1410, 1413-1417, 1419-1440, 1442-1462, 1464-1466, 1468-1479, 1481-1482, 1485-1487, 1489-1490, 1492-1549, 1552-1564, 1566-1571, 1573-1629, 1631-1705, 1707-1771, 1774-1776, 1779-1785, 1788-1789, 1791, 1794-1815, 1817-1828, 1830-1835, 1838-1839, 1841, 1847-1848, 1850, 1853-1854, 1859-1864, 1866, 1868-1869, 1871-1877, 1880, 1882-1921, 1923-1929, 1934-1935, 1937-1938, 1940-1947, 1949, 1951, 1955, 1960-1964, 1967-1972, 1974-1975, 1978-1980, 1982-1986, 1988-1989, 1991, 1994-2006

B9G00100-00103, 107, 109, 111-123, 125, 129, 131, 133-137, 140, 142-143, 146, 148-161, 165-166, 168-171, 173, 175, 178, 180-182, 185-187, 189, 192-196, 199-221

B9M00142-00144, 147, 149, 151-158, 160-165, 167-168, 170-173, 176, 178-179, 181-183, 185-193, 196-198, 209-214, 216-217, 219-221, 223, 228, 231, 234, 237, 239, 241-242, 246-248, 250-252, 254-257, 259-264, 266-274, 276-278, 281-286, 288-301, 305, 307-335, 337, 339-341, 345-352, 354, 360-361, 364-366, 368-373, 375, 377-392, 394-397, 400-401, 404-406, 408-409, 411, 414-415, 417-418, 420, 422-424, 427-435, 437-449, 451, 455-456, 459-461, 466-473, 476-478, 482-492, 494, 496-502, 504-505, 508-510, 512-515, 517-530, 532, 536-537, 539-555, 557-562, 564-568, 570, 572-579, 581-582, 584, 588, 592-594, 599-605, 608-611, 616-637, 639-640, 644, 646, 648-649, 652-653, 658, 662-664, 669-688, 692-701, 703-705, 707-714, 716-751, 753-801, 803-804

D9G00103-00104, 106-107, 109-111, 113, 115-117, 120, 126-132, 134-136, 138-141, 144-145, 148, 152-159, 162-163, 166-169, 172-175, 178-179
160M B9E00115-00116, 118-134, 136-143, 145, 148-203, 205, 207-216, 218-227, 234, 239-241, 244, 249-251, 255-256, 269-270, 272-364

B9L00164, 166-168, 171-174, 176-177, 179-184, 186-194, 196-198, 200-207, 209, 211-219, 222-241, 243-269, 272-284, 286, 288, 290-296, 298-359, 362, 364-365, 367-402, 405-426

B9T00100-00101, 103-116, 119-120, 122-124, 127-141, 143-144

D9T00100-00101, 103-104, 106-107, 109-117
*******Group  5*******
140M B9D00125-00129, 133, 135-136, 146-148, 151, 224, 237, 242, 259-261, 263, 265, 299, 329-331, 335-337, 489-490, 495-496, 505-506, 634, 763, 868, 877, 906, 940, 952, 1067, 1071, 1165, 1169, 1172, 1175, 1180, 1185, 1190, 1194, 1199, 1205-1206, 1208, 1229, 1344, 1349, 1356, 1371, 1376, 1565, 1572, 1829, 1933, 1939, 1953, 1992, 2007-2268

B9G00108, 124, 126-128, 130, 132, 138-139, 141, 144-145, 147, 162-164, 179, 183-184, 197-198, 222-251, 1001-1007

B9M00125-00141, 145-146, 159, 169, 174-175, 177, 194-195, 199-207, 222, 226-227, 230, 233, 235-236, 238, 240, 243-245, 253, 265, 302-304, 336, 338, 342, 344, 355-358, 398, 436, 453, 457, 462, 464-465, 474, 493, 495, 506-507, 511, 516, 533-534, 563, 580, 583, 585, 587, 589, 612-615, 638, 641-643, 645, 647, 650-651, 654-657, 659-660, 689-690, 715, 805-933

D9G00101, 108, 118-119, 121-125, 161, 176, 180-208, 1001-1030
160M B9E00135, 147, 365-395, 397-413

B9L00115-00120, 150-163, 169-170, 175, 185, 195, 199, 242, 289, 361, 366, 403-404, 427-481

B9T00102, 142, 145-160

D9T00119-00122, 124-125, 127-132
*******Group  6*******
140M B9D02271-02275, 2283-2518, 2520-2522

B9G01008-01015

B9M00934-00958

D9G01031-01038
160M B9E00414-00426

B9L00482-00485

B9T00161-00164

D9T00133-00137

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 5P7958 SLEEVE-CA SPLICE (If Required)
1 3635774 Implement #1 Software
1 3635776 Transmission/Chassis Software
1 3638087 140M Equipped with C7 Engine Software
1 3638089 140M Equipped with C9 Engine Software
1 3638091 160M Engine Software
1 3667544 All Wheel Drive Software
1 3667546 Implement #2/#3 Software
1 3697880 Messenger Software
1 3697882 Messenger Software
1 3697884 Messenger Software
1 3697886 Messenger Software
1 3697888 Messenger Software
1 S_B_7881 Operation and Maintenance Manual (140M)
1 S_B_7882 Operation and Maintenance Manual (160M)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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*******
1 5P7958 SLEEVE-CA SPLICE (If Required)
1 3525517 VALVE GP-SOL
1 3584931 SWITCH AS-RPR
1 3584932 SWITCH AS-RPR
1 3635774 Implement #1 Software
1 3635776 Transmission/Chassis Software
1 3638087 140M Equipped with C7 Engine Software
1 3638089 140M Equipped with C9 Engine Software
1 3638091 160M Engine Software
1 3655977 KIT-ACTUATOR (If Required After Inspection)
1 3667544 All Wheel Drive Software
1 3667546 Implement #2/#3 Software
1 3697880 Messenger Software
1 3697882 Messenger Software
1 3697884 Messenger Software
1 3697886 Messenger Software
1 3697888 Messenger Software
1 S_B_7881 Operation and Maintenance Manual (140M)
1 S_B_7882 Operation and Maintenance Manual (160M)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 3*******
1 5P7958 SLEEVE-CA SPLICE (If Required)
1 3525517 VALVE GP-SOL
1 3584932 SWITCH AS-RPR
1 3635774 Implement #1 Software
1 3635776 Transmission/Chassis Software
1 3638087 140M Equipped with C7 Engine Software
1 3638089 140M Equipped with C9 Engine Software
1 3638091 160M Engine Software
1 3655977 KIT-ACTUATOR (If Required After Inspection)
1 3667544 All Wheel Drive Software
1 3667546 Implement #2/#3 Software
1 3697880 Messenger Software
1 3697882 Messenger Software
1 3697884 Messenger Software
1 3697886 Messenger Software
1 3697888 Messenger Software
1 S_B_7881 Operation and Maintenance Manual (140M)
1 S_B_7882 Operation and Maintenance Manual (160M)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 4*******
1 5P7958 SLEEVE-CA SPLICE (If Required)
1 3525517 VALVE GP-SOL
1 3584931 SWITCH AS-RPR
1 3635774 Implement #1 Software
1 3635776 Transmission/Chassis Software
1 3638087 140M Equipped with C7 Engine Software
1 3638089 140M Equipped with C9 Engine Software
1 3638091 160M Engine Software
1 3655977 KIT-ACTUATOR (If Required After Inspection)
1 3667544 All Wheel Drive Software
1 3667546 Implement #2/#3 Software
1 3697880 Messenger Software
1 3697882 Messenger Software
1 3697884 Messenger Software
1 3697886 Messenger Software
1 3697888 Messenger Software
1 S_B_7881 Operation and Maintenance Manual (140M)
1 S_B_7882 Operation and Maintenance Manual (160M)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 5*******
1 5P7958 SLEEVE-CA SPLICE (If Required)
1 3525517 VALVE GP-SOL
1 3635774 Implement #1 Software
1 3635776 Transmission/Chassis Software
1 3638087 140M Equipped with C7 Engine Software
1 3638089 140M Equipped with C9 Engine Software
1 3638091 160M Engine Software
1 3655977 KIT-ACTUATOR (If Required After Inspection)
1 3667544 All Wheel Drive Software
1 3667546 Implement #2/#3 Software
1 3697880 Messenger Software
1 3697882 Messenger Software
1 3697884 Messenger Software
1 3697886 Messenger Software
1 3697888 Messenger Software
1 S_B_7881 Operation and Maintenance Manual (140M)
1 S_B_7882 Operation and Maintenance Manual (160M)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 6*******
1 5P7958 SLEEVE-CA SPLICE (If Required)
1 3635774 Implement #1 Software
1 3635776 Transmission/Chassis Software
1 3638087 140M Equipped with C7 Engine Software
1 3638089 140M Equipped with C9 Engine Software
1 3638091 160M Engine Software
1 3655977 KIT-ACTUATOR (If Required After Inspection)
1 3667544 All Wheel Drive Software
1 3667546 Implement #2/#3 Software
1 3697880 Messenger Software
1 3697882 Messenger Software
1 3697884 Messenger Software
1 3697886 Messenger Software
1 3697888 Messenger Software
1 S_B_7881 Operation and Maintenance Manual (140M)
1 S_B_7882 Operation and Maintenance Manual (160M)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

****Parts Stock ****

Remove all 308-0938 Valve Gp-Actuator with a date code of 0210C or earlier from dealer parts stock.

 
Image1
 
****Affected Product****
Please refer to the rework procedure listed for the group in which the machine you are performing the work on is in.

A new Operation and Maintenance Manual will be provided. Order the new Operation and Maintenance Manual from the following list according to your machine model and serial number in the language needed:

For serial number prefixes B9D, B9G, B9M and D9G (140M), order version -15 or later of the following media:
English - SEBU7881
Danish - SYBU7881
Dutch - SDBU7881
Finnish - SQBU7881
French - SFBU7881
German - SGBU7881
Greek - SHBU7881
Hebrew - SZBU7881 - Delayed Availability - See note below.
Italian - SLBU7881
Latvian - S9BA7881
Lithuanian - S9BU7881
Norwegian - SNBU7881
Polish - SXBU7881
Portuguese - SPBU7881
Romanian - S9BR7881
Russian - SRBU7881
Slovakian - S9BS7881
Slovenian - S9BT7881
Spanish - SSBU7881
Swedish - SWBU7881
Turkish - STBU7881
Arabic - SABU7881 - Delayed Availability - See note below.
Chinese - SCBU7881
Dari - S9BD7881 - Delayed Availability - See note below.

For serial number prefixes B9E, B9L, B9T, D9T (160M), order version -13 or later of the following media:
English - SEBU7882
Danish - SYBU7882
Dutch - SDBU7882
Finnish - SQBU7882
French - SFBU7882
German - SGBU7882
Greek - SHBU7882
Italian - SLBU7882
Norwegian - SNBU7882
Portuguese - SPBU7882
Romanian - S9BR7882
Russian - SRBU7882
Slovenian - S9BT7882
Spanish - SSBU7882
Swedish - SWBU7882
Turkish - STBU7882
Arabic - SABU7882 - Delayed Availability - See note below.
Chinese - SCBU7882
Hebrew - SZBU7882 - Delayed Availability - See note below.

Note: The new Hebrew, Dari, and Arabic language Operation and Maintenance Manuals will not be available initially. Do not order any of these manuals until the proper change level is available. This letter will be revised to remove this note when they are available. If you need additional information concerning the availability call (217) 475-6660 or (217) 475-6292.

Please refer to Service Magazine SEPD1223 "Procedure to Order Engine HP Labels and CE Plates/EEC on Certain 140M Motor Graders" when installing the engine software on 140M machines equipped with C7 engines.

Prior to releasing the machine back into service place printed copy of Service Magazine article titled "New Software That Affects Machine Operation is Now Used on Certain Motor Graders" on the seat in the cab.

In the case that the Actuator Valve Group (Steering Control Module) is being changed, ensure that when the valve is removed, the resolver (as shown as number 7 in Image 1) is not removed with the actuator valve group. This part should remain with the main portion of the steering valve. The result of the resolver being removed from the system would be slow or no steering to the left which could potentially cause E258 events to be generated.
Image1

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

 
 
****Affected Product****
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.5-hour job for Group 1

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 6.5-hour job for Group 2
Include the Valve Gp-Actuator 11 digit date code to the first line of the service claim comments.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 6.5-hour job for Group 3
Include the Valve Gp-Actuator 11 digit date code to the first line of the service claim comments.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 6.5-hour job for Group 4
Include the Valve Gp-Actuator 11 digit date code to the first line of the service claim comments.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 5.5-hour job for Group 5
Include the Valve Gp-Actuator 11 digit date code to the first line of the service claim comments.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 2.5-hour job for Group 6
Include the Valve Gp-Actuator 11 digit date code to the first line of the service claim comments.


PARTS DISPOSITION

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

****Affected Product****
***** NACD *****
Hold all 308-0938 Steering Valves with date codes between 3308A and 0210C for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed workorder paperwork.

Handle all other parts in accordance with your warranty bulletin on warranty parts handling.

***** EAME, LACD, and APD *****
Hold all 308-0938 Steering Valves for 30 days for a possible Parts Return Request (PRR). When returning the part, please label it with a blue warranty tag. Make sure to list the service letter program number on the packing slip and include the closed workorder paperwork.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

Handle all other parts in accordance with your warranty bulletin on warranty parts handling.

 
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 140M AND 160M MOTOR GRADERS

MODELS INVOLVED - 140M, 160M

Dear Caterpillar Product Owner:


The Ripper handle switch/switches need to be replaced on certain 140M and 160M motor graders. The existing switch may fail causing uncommanded movement of the ripper or auxiliary function.
The Valve Gp-Actuator (Primary Steering Control Module) needs to be inspected on certain 140M and 160M motor graders. The existing Valve Gp-Actuator may cause excessive steering system codes to be generated.
The Park Brake Solenoid needs to be replaced on certain 140M and 160M motor graders. The existing Park Brake Solenoid may experience a failure that can prevent it from actuating.


Failure to apply the above changes may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

A new Operation and Maintenance Manual will also be provided.
Updates to the Operation and Maintenance Manual Sections include the following:

Safety Section
-Park Brake Override Procedure

Operation Section
-Blade Lift Modulation
-Optional Warm-Up Procedure for the Hydraulic Oil with Blade Float
-Steering Oil Temperature Monitoring System

Maintenance Section
-Tandem oil and Hydraulic Oil parameters in Lubricant Viscosities Chart

There may be other updates to your Operation and Maintenance Manual depending on the revision of Manual that is currently in the machine. Please review the Sections listed above for detailed updates and review the entire Manual for other updates.

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 07Oct2010 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 07Oct2010 Service Letter


Rework Procedure


Group Number 1  
 
1. Use Cat Electronic Technician service tool to perform the following work:
- Flash Implement #1 ECM with 363-5774 Flash File.
- Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File.
- Flash the All Wheel Drive ECM (if applicable) with 366-7544 Flash File.
- Flash the Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 140M Engine ECM (Equipped with a C7 Engine) with 363-8087 Flash File.
- Flash 140M Engine ECM (Equipped with a C9 Engine) with 363-8089 Flash File.
- Flash 160M Engine ECM with 363-8091 Flash File.
- Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number:
369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch).
369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian).
369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish).
369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese).
369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian).

NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb.

NOTE: The Transmission/Chassis, Implement #1, #2, #3, and the All Wheel Drive ECMs can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL.
 
2. On both the Right and Left Hand Steering Cylinders, locate the Sensor set screw hole (1) and clean out any debris.
Tighten the 8T-5070 set screw (2) to a torque of 25 +/- 3 N.m
Fill the set screw hole with one of the following:
Loctite 515 or equivalent.
Image1.2.1
 
 
Group Number 2  
 
1. Remove the right hand rear valve cover (1).
Image2.1.1
 
Inspect the Valve Gp-Actuator (Steering Control Module) (1) for the date code. The date code format is as follows:
The first 2 numbers refer to the week (A) of which the module was built, the second two numbers refer to the year (B). The letter following the numbers refers to the day of the week (C) and the last six numbers is the serial number (D).
Image2.2.1
 
If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the Valve Gp-Actuator (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer, record 11-digit date code for the valve on the work order so that it can be entered into the comment section of the warranty claim. Reinstall the right hand valve cover. If the date code is 0210D or later, reinstall the right hand valve cover and proceed with flashing the new software as described below:

Use Cat Electronic Technician service tool to perform the following work:
- Flash Implement #1 ECM with 363-5774 Flash File.
- Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File.
- Flash the All Wheel Drive ECM (if applicable) with 366-7544 Flash File.
- Flash the Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 140M Engine ECM (Equipped with a C7 Engine) with 363-8087 Flash File.
- Flash 140M Engine ECM (Equipped with a C9 Engine) with 363-8089 Flash File.
- Flash 160M Engine ECM with 363-8091 Flash File.
- Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number:
369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch).
369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian).
369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish).
369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese).
369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian).

NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb.

NOTE: The Transmission/Chassis, Implement #1, #2, and #3, and the All Wheel Drive ECMs can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL.
 
2. Remove the existing 248-5523 Park Brake Solenoid and replace with a new 352-5517 Solenoid.
The solenoid (A) is located on the top left hand side of the transmission. Please refer to image 2.4.1 for location.
Image2.4.1
 
3. Remove and replace the switches in the ripper handle. Switch number 2 has float capability and should be replaced with 358-4932 Switch As-Rpr. Switch number 1 does not have float capability and should be replaced with 358-4931 Switch As-Rpr.
Image2.5.1
 
4. On both the Right and Left Hand Steering Cylinders, locate the Sensor set screw hole (1) and clean out any debris.
Tighten the 8T-5070 set screw (2) to a torque of 25 +/- 3 N.m
Fill the set screw hole with one of the following:
Loctite 515 or equivalent.
Image2.6.1
 
 
Group Number 3  
 
1. Remove the right hand rear valve cover (1).
Image3.1.1
 
Inspect the Valve Gp-Actuator (Steering Control Module) (1) for the date code. The date code format is as follows:
The first 2 numbers refer to the week (A) of which the module was built, the second two numbers refer to the year (B). The letter following the numbers refers to the day of the week (C) and the last six numbers is the serial number (D).
Image3.2.1
 
If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the Valve Gp-Actuator (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer, record 11-digit date code for the valve on the work order so that it can be entered into the comment section of the warranty claim. Reinstall the right hand valve cover. If the date code is 0210D or later, reinstall the right hand valve cover and proceed with flashing the new software as described below:

Use Cat Electronic Technician service tool to perform the following work:
- Flash Implement #1 ECM with 363-5774 Flash File.
- Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File.
- Flash the All Wheel Drive ECM (if applicable) with 366-7544 Flash File.
- Flash the Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 140M Engine ECM (Equipped with a C7 Engine) with 363-8087 Flash File.
- Flash 140M Engine ECM (Equipped with a C9 Engine) with 363-8089 Flash File.
- Flash 160M Engine ECM with 363-8091 Flash File.
- Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number:
369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch).
369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian).
369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish).
369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese).
369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian).

NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb.

NOTE: The Transmission/Chassis, Implement #1, #2, and #3, and the All Wheel Drive ECMs can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL.
 
2. Remove the existing 248-5523 Park Brake Solenoid and replace with a new 352-5517 Solenoid.
The solenoid (A) is located on the top left hand side of the transmission. Please refer to image 3.4.1 for location.
Image3.4.1
 
3. Remove and replace the switch in the ripper handle. The switch has float capability and should be replaced with 358-4932 Switch As-Rpr.
Image3.5.1
 
4. On both the Right and Left Hand Steering Cylinders, locate the Sensor set screw hole (1) and clean out any debris.
Tighten the 8T-5070 set screw (2) to a torque of 25 +/- 3 N.m
Fill the set screw hole with one of the following:
Loctite 515 or equivalent.
Image3.6.1
 
 
Group Number 4  
 
1. Remove the right hand rear valve cover (1).
Image4.1.1
 
Inspect the Valve Gp-Actuator (Steering Control Module) (1) for the date code. The date code format is as follows:
The first 2 numbers refer to the week (A) of which the module was built, the second two numbers refer to the year (B). The letter following the numbers refers to the day of the week (C) and the last six numbers is the serial number (D).
Image4.2.1
 
If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the Valve Gp-Actuator (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer, record 11-digit date code for the valve on the work order so that it can be entered into the comment section of the warranty claim. Reinstall the right hand valve cover. If the date code is 0210D or later, reinstall the right hand valve cover and proceed with flashing the new software as described below:

Use Cat Electronic Technician service tool to perform the following work:
- Flash Implement #1 ECM with 363-5774 Flash File.
- Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File.
- Flash the All Wheel Drive ECM (if applicable) with 366-7544 Flash File.
- Flash the Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 140M Engine ECM (Equipped with a C7 Engine) with 363-8087 Flash File.
- Flash 140M Engine ECM (Equipped with a C9 Engine) with 363-8089 Flash File.
- Flash 160M Engine ECM with 363-8091 Flash File.
- Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number:
369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch).
369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian).
369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish).
369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese).
369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian).

NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb.

NOTE: The Transmission/Chassis, Implement #1, #2, and #3, and the All Wheel Drive ECMs can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL.
 
2. Remove the existing 248-5523 Park Brake Solenoid and replace with a new 352-5517 Solenoid.
The solenoid (A) is located on the top left hand side of the transmission. Please refer to image 2.4.1 for location.
Image4.4.1
 
3. Remove and replace the switch in the ripper handle. The switch does not have float capability and should be replaced with 358-4931 Switch As-Rpr.
Image4.5.1
 
4. On both the Right and Left Hand Steering Cylinders, locate the Sensor set screw hole (1) and clean out any debris.
Tighten the 8T-5070 set screw (2) to a torque of 25 +/- 3 N.m
Fill the set screw hole with one of the following:
Loctite 515 or equivalent.
Image4.6.1
 
 
Group Number 5  
 
1. Remove the right hand rear valve cover (1).
Image5.1.1
 
Inspect the Valve Gp-Actuator (Steering Control Module) (1) for the date code. The date code format is as follows:
The first 2 numbers refer to the week (A) of which the module was built, the second two numbers refer to the year (B). The letter following the numbers refers to the day of the week (C) and the last six numbers is the serial number (D).
Image5.2.1
 
If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the Valve Gp-Actuator (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer, record 11-digit date code for the valve on the work order so that it can be entered into the comment section of the warranty claim. Reinstall the right hand valve cover. If the date code is 0210D or later, reinstall the right hand valve cover and proceed with flashing the new software as described below:

Use Cat Electronic Technician service tool to perform the following work:
- Flash Implement #1 ECM with 363-5774 Flash File.
- Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File.
- Flash the All Wheel Drive ECM (if applicable) with 366-7544 Flash File.
- Flash the Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 140M Engine ECM (Equipped with a C7 Engine) with 363-8087 Flash File.
- Flash 140M Engine ECM (Equipped with a C9 Engine) with 363-8089 Flash File.
- Flash 160M Engine ECM with 363-8091 Flash File.
- Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number:
369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch).
369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian).
369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish).
369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese).
369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian).

NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb.

NOTE: The Transmission/Chassis, Implement #1, #2, #3, and the All Wheel Drive ECMs can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL.
 
2. Remove the existing 248-5523 Park Brake Solenoid and replace with a new 352-5517 Solenoid.
The solenoid (A) is located on the top left hand side of the transmission. Please refer to image 2.4.1 for location.
Image5.4.1
 
3. On both the Right and Left Hand Steering Cylinders, locate the Sensor set screw hole (1) and clean out any debris.
Tighten the 8T-5070 set screw (2) to a torque of 25 +/- 3 N.m
Fill the set screw hole with one of the following:
Loctite 515 or equivalent.
Image5.5.1
 
 
Group Number 6  
 
1. Remove the right hand rear valve cover (1).
Image6.1.1
 
Inspect the Valve Gp-Actuator (Steering Control Module) (1) for the date code. The date code format is as follows:
The first 2 numbers refer to the week (A) of which the module was built, the second two numbers refer to the year (B). The letter following the numbers refers to the day of the week (C) and the last six numbers is the serial number (D).
Image6.2.1
 
If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the Valve Gp-Actuator (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer, record 11-digit date code for the valve on the work order so that it can be entered into the comment section of the warranty claim. Reinstall the right hand valve cover. If the date code is 0210D or later, reinstall the right hand valve cover and proceed with flashing the new software as described below:

Use Cat Electronic Technician service tool to perform the following work:
- Flash Implement #1 ECM with 363-5774 Flash File.
- Flash Implement #2 and Implement #3 ECM (if applicable) with 366-7546 Flash File.
- Flash the All Wheel Drive ECM (if applicable) with 366-7544 Flash File.
- Flash the Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 140M Engine ECM (Equipped with a C7 Engine) with 363-8087 Flash File.
- Flash 140M Engine ECM (Equipped with a C9 Engine) with 363-8089 Flash File.
- Flash 160M Engine ECM with 363-8091 Flash File.
- Flash the Messenger Monitor Display with the flash file containing the appropriate languages. Reference the following list for the appropriate part number:
369-7880 Software-Monitor (English, Portuguese, Spanish, French, German, Dutch).
369-7882 Software-Monitor (English, Portuguese, Danish, Finnish, Swedish, Norwegian).
369-7884 Software-Monitor (English, Portuguese, Italian, Greek, Hebrew, Turkish).
369-7886 Software-Monitor (English, Portuguese, Russian, Arabic, Chinese).
369-7888 Software-Monitor (English, Portuguese, Romanian, Slovenian, Indonesian).

NOTE: New machine flash files are released periodically. Ensure you are using the latest flash files by downloading the files from SISWeb.

NOTE: The Transmission/Chassis, Implement #1, #2, #3, and the All Wheel Drive ECMs can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL.
 
2. On both the Right and Left Hand Steering Cylinders, locate the Sensor set screw hole (1) and clean out any debris.
Tighten the 8T-5070 set screw (2) to a torque of 25 +/- 3 N.m
Fill the set screw hole with one of the following:
Loctite 515 or equivalent.
Image6.4.1
 
 

Caterpillar Information System:

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