PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 16M MOTOR GRADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 16M MOTOR GRADERS

Usage:

REBE6398-01

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18Nov2010

(Revised 21Dec2010)

U-465

A-382

D-409

O-408

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Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 16M MOTOR GRADERS
7610 7620 7601 7332 4307 5051 1130 1902 4322		PI10830

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10830" 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 "PI10830" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:

This Revised Service Letter replaces the 18Nov2010 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). Changes have also been made to quantities in the Parts Needed to include both LH and RH covers for the steering harnesses as well as additional parts to cover both LH and RH AutoLube hose modifications.

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PROBLEM

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The ripper handle switch/switches need to be replaced on certain 16M Motor Graders. The existing switch may fail causing uncommanded movement of the ripper or auxiliary function.

The actuator valve group (Primary Steering Control Module) needs to be inspected on certain 16M Motor Graders. The existing actuator valve group may cause excessive steering system codes to be generated.

The park brake solenoid needs to be replaced on certain 16M 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 16M 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 99 kph or 61 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.
-A software change was made to reduce the time required for the engine speed to recover during 4-5R and 5-6R upshifts.

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

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Model	Identification Number
*****Group 1*****
16M	B9H00756-00833

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*****Group 2*****
16M	B9H00190, 528, 543

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*******Group 3*******

16M

B9H00112-00118, 121-124, 127, 130, 135, 139, 141, 148-149, 159-165, 167, 170-173, 177-181, 186-188, 194-195, 200-201, 206-207, 217-220, 223, 225-234, 236, 244-248, 253, 255-256, 260-262, 265, 271-274, 276-277, 280-281, 283, 285, 290-293, 295-296, 298-304, 306-313, 315-316, 318, 320-324, 333-336, 339-341, 343-346, 350-355, 361, 363, 366-368, 372-374, 379, 381, 383, 386-389, 391-392, 396, 398-399, 407-409, 411, 420, 423-425, 429-433, 447-448, 450-451, 453, 456-459, 462, 466-471, 485-493, 499-500, 504-506, 508, 510-511, 513, 518, 523-524, 526-527, 530-531, 534, 536-537, 541-542, 549, 551, 553, 559-560, 564-568, 571, 579, 586, 595, 601-603, 605-606, 609, 614, 616, 629-631, 635, 637, 639, 641, 647-648, 653-654

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*******Group 4*******

16M

B9H00110, 119-120, 125-126, 128-129, 132-134, 136-137, 140, 144, 146-147, 150-151, 153-158, 166, 168-169, 174-176, 182-184, 189, 191-193, 196-199, 202-205, 208-210, 212-216, 221-222, 224, 235, 237-243, 250-252, 254, 257-259, 263-264, 266-270, 278-279, 282, 284, 286, 288-289, 294, 297, 305, 314, 317, 319, 325, 327-332, 337-338, 342, 347-349, 356-360, 362, 364-365, 369-371, 376-378, 380, 382, 384-385, 394-395, 401-404, 406, 410, 412-419, 421, 426-428, 434-441, 443, 445-446, 449, 454-455, 460-461, 463-465, 472-484, 494-498, 501-503, 507, 509, 512, 514-517, 519-522, 525, 529, 532-533, 535, 538-540, 545-548, 550, 552, 554-556, 558, 561-563, 569-570, 572-575, 577-578, 580-585, 587-589, 591-594, 596, 598-600, 604, 607-608, 610, 612-613, 615, 617, 619-621, 623-628, 632-634, 636, 640, 642-646, 649-652

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*****Group 5*****
16M	B9H00111, 145, 185, 287, 326, 393, 397, 405, 544, 576, 597, 611, 622

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*****Group 6*****
16M	B9H00138, 142-143, 152, 275, 375, 400, 442, 444, 638, 655-656, 658-661, 664, 666, 668-669, 672-674, 679, 684, 687-689, 691, 694-696, 703-704, 712, 717

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*****Group 7*****
16M	B9H00100-00109, 131, 211, 249, 390, 422, 452, 557, 590, 618, 657, 662-663, 665, 667, 670-671, 675-678, 680-683, 685-686, 690, 692-693, 697-702, 705-711, 713-716, 718-728

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*****Group 8*****
16M	B9H00729-00755

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
1	4P7581	CLIP-LADDER
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
5	8T4121	WASHER-HARD
5	8T4137	BOLT
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
2	3S2093	STRAP-CABLE
2	4K8302	CLIP
1	4P7581	CLIP-LADDER
2	5C7261	NUT-HEX
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
9	8T4121	WASHER-HARD
2	8T4136	BOLT
7	8T4137	BOLT
1	8T4179	BOLT
1	8T4223	WASHER-HARD
2	8T4224	WASHER-HARD
4	9M8406	CLIP-LOOP
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
1	3004957	CABLE AS.
1	3005583	BRACKET AS.
1	3525517	VALVE GP-SOL
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3584931	SWITCH AS-RPR
1	3584932	SWITCH AS-RPR
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
1	3655978	KIT-ACTUATOR (If Required After Inspection)
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
2	3S2093	STRAP-CABLE
2	4K8302	CLIP
1	4P7581	CLIP-LADDER
2	5C7261	NUT-HEX
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
9	8T4121	WASHER-HARD
2	8T4136	BOLT
7	8T4137	BOLT
1	8T4179	BOLT
1	8T4223	WASHER-HARD
2	8T4224	WASHER-HARD
4	9M8406	CLIP-LOOP
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
1	3004957	CABLE AS.
1	3005583	BRACKET AS.
1	3525517	VALVE GP-SOL
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3584931	SWITCH AS-RPR
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
1	3655978	KIT-ACTUATOR (If Required After Inspection)
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
1	4P7581	CLIP-LADDER
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
5	8T4121	WASHER-HARD
5	8T4137	BOLT
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3584931	SWITCH AS-RPR
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
1	3655978	KIT-ACTUATOR (If Required After Inspection)
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
1	4P7581	CLIP-LADDER
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
5	8T4121	WASHER-HARD
5	8T4137	BOLT
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
1	3525517	VALVE GP-SOL
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3584931	SWITCH AS-RPR
1	3584932	SWITCH AS-RPR
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
1	3655978	KIT-ACTUATOR (If Required After Inspection)
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
2	3S2093	STRAP-CABLE
2	4K8302	CLIP
1	4P7581	CLIP-LADDER
2	5C7261	NUT-HEX
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
9	8T4121	WASHER-HARD
2	8T4136	BOLT
7	8T4137	BOLT
1	8T4179	BOLT
1	8T4223	WASHER-HARD
2	8T4224	WASHER-HARD
4	9M8406	CLIP-LOOP
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
1	3004957	CABLE AS.
1	3005583	BRACKET AS.
1	3525517	VALVE GP-SOL
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
1	3655978	KIT-ACTUATOR (If Required After Inspection)
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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 7*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
1	4P7581	CLIP-LADDER
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
5	8T4121	WASHER-HARD
5	8T4137	BOLT
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
1	3525517	VALVE GP-SOL
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
1	3655978	KIT-ACTUATOR (If Required After Inspection)
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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 8*****
2	2D1683	ELBOW-90 DEG (If Equipped with AutoLube)
1	4P7581	CLIP-LADDER
1	5P7958	SLEEVE-CA SPLICE (If Required)
2	7K1181	STRAP-CABLE
6	8M2770	CLIP-LOOP
5	8T4121	WASHER-HARD
5	8T4137	BOLT
1	1160118	CLIP
1	1325789	CLIP-LADDER
2	2679432	ADAPTER (If Equipped With AutoLube)
2	2924311	FITTING - SWIVEL (If Equipped With AutoLube)
2	3555085	PLATE AS.
2	3555086	COVER
1	3555087	HARNESS AS.
1	3555088	HARNESS AS.
1	3614431	ROD
1	3635774	Implement #1 Software
1	3635776	Transmission/Chassis Software
1	3651277	HOSE AS
1	3651278	HOSE AS
1	3655978	KIT-ACTUATOR (If Required After Inspection)
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	3701071	16M Engine Software
1	S_B_7884	Operation and Maintenance Manual (16M)
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

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****Parts Stock ****

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

Image1

****Affected Product****

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Refer to the rework procedure for the group that your machine is in.

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

Order version -11 or later of the following media:

English - SEBU7884
Spanish - SSBU7884
Chinese - SCBU7884
Portuguese - SPBU7884
French - SFBU7884
Swedish - SWBU7884
Russian - SRBU78884
Italian - SLBU7884
Danish - SYBU7884
Finnish - SQBU7884
German - SGBU7884
Norwegian - SNBU7884
Romanian - S9BR7884
Dutch - SDBU7884
Turkish - STBU7884
Bulgarian - S9BB7884
Estonian - S9BE7884
Japanese - SJBU7884
Serbian - S9BV7884

Remove the 5P7958 Sleeve-Ca Splice from the lanyard that secures the O&MM in the cab. Secure the new O&MM to the lanyard using a 5P7958 Sleeve-Ca Splice or equivalent.

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

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Image1

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

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

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 9.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 16.5-hour job for Group 2
Include the 11 digit date code for the actuator valve group in the first line of the service claim comments.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 16.5-hour job for Group 3
Include the 11 digit date code for the actuator valve group in the first line of the service claim comments.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 11.5-hour job for Group 4
Include the 11 digit date code for the actuator valve group in the first line of the service claim comments.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 14.5-hour job for Group 5
Include the 11 digit date code for the actuator valve group in the first line of the service claim comments.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 16.0-hour job for Group 6
Include the 11 digit date code for the actuator valve group in the first line of the service claim comments.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 14.0-hour job for Group 7
Include the 11 digit date code for the actuator valve group in the first line of the service claim comments.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 11.0-hour job for Group 8
Include the 11 digit date code for the actuator valve group in the first line of the service claim comments.

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

***** NACD *****
Hold all 308-0938 Actuator Valve Groups 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 work order paperwork.

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

***** EAME, LACD, and APD *****
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 INSTALLING NEW SOFTWARE AND CERTAIN HARDWARE COMPONENTS ON CERTAIN 16M MOTOR GRADERS

MODELS INVOLVED - 16M Motor Graders

Dear Caterpillar Product Owner:

The ripper handle switch/switches need to be replaced on the products listed below. The existing switch may fail causing uncommanded movement of the ripper or auxiliary function.
The actuator valve group (Primary Steering Control Module) needs to be inspected on the products listed below. The existing actuator valve group may cause excessive steering system codes to be generated.
The park brake solenoid needs to be replaced on the products listed below. 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
-Transmission Under Speed Protection Strategy
-Optional Warm-Up Procedure for the Hydraulic Oil with Blade Float
- Steering Oil Temperature Monitoring System

Maintenance Section
- Lubricant Viscosities Chart (Tandem oil and Hydraulic Oil)

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 18Nov2010 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 18Nov2010 Service Letter

Rework Procedure

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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 Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 16M Engine ECM with 370-1071 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 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 Nm.
Fill the set screw hole with Loctite 515 or equivalant.

Image1.2.1

3. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

4. Remove hose (A) in Image 1.4.1 and replace with a 365-1278 Hose Assembly.

5. Remove hose (B) in Image 1.4.1 and replace with a 365-1277 Hose Assembly.

6. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 1.4.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

7. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt and 8T-4121 Washer as seen in Image 1.4.1.

Image1.4.1

8. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace the 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675/">294-0675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 1.5.1.

Repeat Steps 7 and 8 for both sides of the machine.

Image1.5.1

Group Number 2

1. Remove access panel (2).

NOTE: Image 2.1.1 is a typical representation of the access panel.

Image2.1.1

Inspect the actuator valve group (Steering Control Module) (1) for the date code. The date code format is as follows:
The first 2 numbers refer to the week which the module was built (A), 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 actuator valve group (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer. Record the 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 Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 16M Engine ECM with 370-1071 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 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. Refer to Image 2.4.1 for the 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 a 358-4932 Switch Assembly. Switch number 1 does not have float capability and should be replaced with a 358-4931 Switch Assembly.

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 Nm.
Fill the set screw hole with Loctite 515 or equivalant.

Image2.6.1

5. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

6. Refer to Special Instruction, REHS5517, "Procedure to Replace Starter Cable Assembly on Certain Motor Graders" for instructions on replacing the starter cable assembly.

7. Remove hose (A) in Image 2.9.1 and replace with a 365-1278 Hose Assembly.

8. Remove hose (B) in Image 2.9.1 and replace with a 365-1277 Hose Assembly.

9. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 2.9.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

10. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt, and 8T-4121 Washer as seen in Image 2.9.1.

Image2.9.1

11. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace the 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675/">294-0675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 2.10.1.

Repeat Steps 10 and 11 for both sides of the machine.

Group Number 3

1. Remove access panel (2).

NOTE: Image 3.1.1 is a typical representation of the access panel.

Image3.1.1

Image3.2.1

Image3.4.1

3. Remove and replace the switch in the ripper handle. The switch does not have float capability and should be replaced with a 358-4931 Switch Assembly.

Image3.5.1

Image3.6.1

5. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

6. Refer to Special Instruction, REHS5517, "Procedure to Replace Starter Cable Assembly on Certain Motor Graders" for instructions on replacing the starter cable assembly.

7. Remove hose (A) in Image 3.9.1 and replace with a 365-1278 Hose Assembly.

8. Remove hose (B) in Image 3.9.1 and replace with a 365-1277 Hose Assembly.

9. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 3.9.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

10. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt, and 8T-4121 Washer as seen in Image 3.9.1.

Image3.9.1

11. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace the 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675/">294-0675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 3.10.1.

Repeat Steps 10 and 11 for both sides of the machine.

Group Number 4

1. Remove access panel (2).

NOTE: Image 4.1.1 is a typical representation of the access panel.

Image4.1.1

Image4.2.1

If the date code is 0210C (Week 2 of 2010, Wednesday) or earlier, remove and replace the actuator valve group (Steering Control Module) ensuring the new valve has a date code of 0210D (Week 2 of 2010, Thursday) or newer. Record the 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 Transmission/Chassis ECM with 363-5776 Flash File.
- Flash 16M Engine ECM with 370-1071 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 can be flashed over the J1939 Data Link. The Messenger ECM is flashed over CDL.

2. Remove and replace the switch in the ripper handle. The switch does not have float capability and should be replaced with a 358-4931 Switch Assembly.

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 Nm.
Fill the set screw hole with Locrite 515 or equivalent.

Image4.5.1

4. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

Image4.6.1

5. Remove hose (A) in Image 4.7.1 and replace with a 365-1278 Hose Assembly.

6. Remove hose (B) in Image 4.7.1 and replace with a 365-1277 Hose Assembly.

7. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 4.7.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

8. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt, and 8T-4121 Washer as seen in Image 4.7.1.

Image4.7.1

9. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace the 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675/">294-0675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 4.8.1.

Repeat Steps 8 and 9 for both sides of the machine.

Image4.8.1

Group Number 5

1. Remove access panel (2).

NOTE: Image 5.1.1 is a typical representation of the access panel.

Image5.1.1

Image5.2.1

Image5.4.1

Image5.5.1

Image5.6.1

5. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

6. Remove hose (A) in Image 5.8.1 and replace with a 365-1278 Hose Assembly.

7. Remove hose (B) in Image 5.8.1 and replace with a 365-1277 Hose Assembly.

8. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 5.8.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

9. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt, and 8T-4121 Washer as seen in Image 5.8.1.

Image5.8.1

10. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace the 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 5.9.1.

Repeat Steps 9 and 10 for both sides of the machine.

Image5.9.1

Group Number 6

1. Remove access panel (2).

NOTE: Image 6.1.1 is a typical representation of the access panel.

Image6.1.1

Image6.2.1

Image6.4.1

4. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

Image6.6.1

5. Refer to Special Instruction, REHS5517, "Procedure to Replace Starter Cable Assembly on Certain Motor Graders" for instructions on replacing the starter cable assembly.

6. Remove hose (A) in Image 6.8.1 and replace with a 365-1278 Hose Assembly.

7. Remove hose (B) in Image 6.8.1 and replace with a 365-1277 Hose Assembly.

9. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 6.8.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

10. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt and 8T-4121 Washer as seen in Image 6.8.1.

Image6.8.1

11. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace the 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675/">294-0675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 6.9.1.

Repeat Steps 10 and 11 for both sides of the machine.

Image6.9.1

Group Number 7

1. Remove access panel (2).

NOTE: Image 7.1.1 is a typical representation of the access panel.

Image7.1.1

Image7.2.1

Image7.4.1

Image7.5.1

4. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

5. Remove hose (A) in Image 7.7.1 and replace with a 365-1278 Hose Assembly.

6. Remove hose (B) in Image 7.7.1 and replace with a 365-1277 Hose Assembly.

7. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 7.7.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

8. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt and 8T-4121 Washer as seen in Image 7.7.1.

Image7.7.1

9. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace the 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675/">294-0675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 7.8.1.

Repeat Steps 8 and 9 for both sides of the machine.

Image7.8.1

Group Number 8

1. Remove access panel (2).

NOTE: Image 8.1.1 is a typical representation of the access panel.

Image8.1.1

Image8.2.1

Image8.4.1

3. Refer to Special Instruction, REHS5516, "Procedure to Rework the Steering Cylinder Sensor Harness Assembly" for instructions on replacing the steering cylinder sensor harness.

4. Remove hose (A) in Image 8.6.1 and replace with a 365-1278 Hose Assembly.

5. Remove hose (B) in Image 8.6.1 and replace with a 365-1277 Hose Assembly.

6. Remove the 264-1164 Rod (C) from the 264-1163 Steering Link Group as seen in Image 8.6.1 and replace with a 361-4431 Rod. Reinstall and refer to Axle Toe-In (Front) - Adjust in media number RENR8462 for adjusting the toe in.

8. If the machine is equipped with Autolube, remove and discard the 302-8255 Adapter, 2R-1922 Connector, 5P-7467 Clip, 5P-9085 Clip-Loop, 8T-4195 Bolt and 8T-4121 Washer as seen in Image 8.6.1.

Image8.6.1

7. Replace the 302-8255 Adapter with a 267-9432 Adapter and 292-4311 Fitting-Swivel. Replace 2R-1922 Connector with a 2D-1683 Elbow-90 degree. Remove the 2940675/">294-0675 Hose Assembly. Remove the 171-8964 Coupling from one end of the hose and cut 430mm of hose length from the 171-9629 Hose. Reinstall the 171-8964 Coupling and install the hose back onto the machine as seen in Image 8.7.1.

Repeat Steps 6 and 7 for both sides of the machine.