PRODUCT SUPPORT PROGRAM FOR REPLACING TRANS SOLENOID VALVE CARTRIDGES ON CERTAIN 980G II, 990II, 992G, 994D WHEEL LOADERS; 24H MOTORGRADERS; D11R TRACK TYPE TRACTORS; 769D, 771D, 773E, 775E, 777D, 785C, 789C, 793C OFF HIGHWAY TRUCKS; 740 ARTICULATED

Usage:

SEBE8716-01

March 28, 2004
(Revised April 2004)
U-92
A-61
D-71
O-75

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*Before or* *after failure* *Parts stock action needed*	PRODUCT SUPPORT PROGRAM FOR REPLACING TRANS SOLENOID VALVE CARTRIDGES ON CERTAIN 980G II, 990II, 992G, 994D WHEEL LOADERS; 24H MOTORGRADERS; D11R TRACK TYPE TRACTORS; 769D, 771D, 773E, 775E, 777D, 785C, 789C, 793C OFF HIGHWAY TRUCKS; 740 ARTICULATED TRUCKS, 621G, 623G, 627G, 631G, 637G, AND 657E TRACTOR SCRAPERS
4805		PS41543

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41543" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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 March 28, 2004 Service Letter. Changes have been made to the models listed in the Title and Problem.

TERMINATION DATE

March 31, 2005

PROBLEM

All Trans Solenoid Valve Cartridge Assemblies within the suspect date code range need to be replaced on certain 980G II, 990II, 992G, 994D Wheel Loaders; 24H Motorgraders; D11R Track Type Tractors; 769D, 771D, 773E, 775E, 777D, 785C, 789C, 793C Off Highway Trucks; 740 Articulated Trucks, 621G, 623G, 627G, 631G, 637G, and 657E Tractor Scrapers. Cracks have been found in certain 1078611 Solenoid Valve Cartridge Assemblies that may cause the solenoid spool valve to malfunction.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 *
980G II	AWH1442, 1443, 1455, 1456, 1458, 1460, 1461, 1464, 1468-1471, 1473, 1474, 1476, 1477, 1480, 1482, 1484-1486, 1489, 1491, 1493-1497, 1500-1502, 1507, 1514-1519, 1521, 1523-1526, 1528-1531, 1533, 1536-1538, 1540-1542, 1544-1550, 1552-1557, 1559, 1560, 1566, 1567, 1569-1571, 1574, 1577, 1582, 1583, 1585, 1587, 1589, 1592, 1609 AXG853, 855, 857, 858, 860, 862-865, 867, 868
24H	7KK235-237
* Group 2 *
990 II	BCR246
992G	ADZ575-583, 585-587
994D	3TZ304
D11R	7PZ745-782, 784 AAF210-213
* Group 3 *
740	AXM1205, 1211, 1217, 1218, 1220, 1223, 1225, 1227, 1228, 1240, 1242, 1246-1249, 1251, 1253, 1254, 1256-1263, 1266-1276, 1278, 1280-1284, 1286-1306, 1308-1310, 1312-1324
740EJ	AZZ328, 330-334
777D	AGC1338, 1345, 1348, 1350-1354, 1358, 1361-1364, 1368-1371, 1373, 1374
785C	APX382-384, 391, 392, 394
789C	2BW619-623, 632
793C	ATY623, 625-632, 634, 636, 639-642, 650, 652
769D	BBB346-362, 364, 367-371
771D	BCA248-256, 258-262
773E	BDA524, 525, 528-530, 536-552, 554-560, 562
775E	BEC331, 333-336, 338-342, 344-350, 352, 355, 356, 358
* Group 4 *
621G	CEN304-307, 310, 312-316, 319, 322
623G	CES456-459, 461-466
631G	CLR405, 410, 411, 413-415
637G	CEH351, 353
* Group 5 *
627G	CEX402-414, 416, 417, 420
657E	5YR558, 560 6TR420-422

PARTS NEEDED

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Qty	Part Number	Description
* Group 1 *
6	1078611	CARTRIDGE AS
* Group 2 *
5	1078611	CARTRIDGE AS
* Group 3 *
3	1078611	CARTRIDGE AS
* Group 4 *
2	1078611	CARTRIDGE AS
* Group 5 *
4	1078611	CARTRIDGE AS

ACTION REQUIRED

***** Parts Stock *****

Remove all 1078611 with date codes 0340 through 0349 from parts stock.

***** Affected Product *****

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

***** Parts Stock *****

Submit one claim for all 1078611 removed from parts stock.

***** For D11R *****

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-4000	100%	1.0	0	0	0	0
NOTE: This is a 1.0?hr job.

***** For 621G, 623G, 631G, 637G, 740, 769D, 771D, 773E, 775E, 777D, 785C, 789C, 789C,

793C,980GII, 990 II, 992G, 994D, *****

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-4000	100%	2.0	0	0	0	0
NOTE: This is a 2.0?hr job.

***** For 627G and 657E *****

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-4000	100%	4.0	0	0	0	0
NOTE: This is a 4.0?hr job.

***** For 24H *****

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-4000	100%	5.0	0	0	0	0
NOTE: This is a 5.0?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Clean the work area before rework to prevent contamination. Refer to Table 1 for the correct service manual for removal/replacement of the cartridges.
Replace all cartridges in the suspect date code range of 0340 through 0349. Refer to Illustration 1 for the location of the date code on the cartridge.
Confirm proper operation of the transmission by operating the machine in all gears.

Illustration 1

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Sales Model	Machine S/N Prefixes	Service Manual(s)
980GII	AWH, AXG	RENR4378
24H	7KK	SENR1437
990 II	BCR	RENR6265
992G	ADZ	SENR5894
994D	3TZ	RENR2034
D11R	7PZ	SENR1782
769D/771D	BBB, BCA	SENR1551
773E/775E	BDA, BEC	SENR1574
777D	AGC	RENR3366
740	AXM, AZZ	RENR5139
785C	APX	SENR1490
789C	2BW	SENR1524
793C	ATY	RENR2534
621G/623G	CEN,CES	RENR6804
631G/637G	CLR, CEH	RENR4072
657E	5YR, 6TR	SENR9096 (front trans) SENR9097 (rear trans)
627G	CEX	RENR6804 (front trans) RENR6815 (rear trans)