PRODUCT SUPPORT PROGRAM FOR UPDATING THE GRAPPLE AUTO-GRAB PRESSURE SWITCH TO A PRESSURE SENSOR ON CERTAIN 525B, 535B AND 545 WHEEL SKIDDERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE GRAPPLE AUTO-GRAB PRESSURE SWITCH TO A PRESSURE SENSOR ON CERTAIN 525B, 535B AND 545 WHEEL SKIDDERS

Usage:

SEBE7865-01

December 14, 2001
(Revised January 2003)
U-345
A-243
AU-235
S-185
O-265

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE GRAPPLE AUTO-GRAB PRESSURE SWITCH TO A PRESSURE SENSOR ON CERTAIN 525B, 535B AND 545 WHEEL SKIDDERS
1408 5570 5057		PS50359

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50359" as the Part number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

NOTE: This Revised Service Letter replaces the December 14, 2001 Service Letter. Changes have been made to the Rework Procedure.

TERMINATION DATE

December 31, 2003

PROBLEM

The grapple pressure switch may fail on certain 525B, 535B, and 545 Wheel Skidders. If the grapple pressure switch fails, an update to a pressure sensor for increased service life is needed. Changing to the sensor requires installation of a hose, which acts as an accumulator to protect the sensor from pressure spikes in the hydraulic system. This update also requires a software change to the grapple/transmission control, and some minor additions and changes to the Skidder wiring.

AFFECTED PRODUCT

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Model	Identification Number
* Group 1 (with winch) *
525B	3KZ226-228, 231, 232, 234-238, 242, 245, 246, 248, 250- 252, 255-257, 259, 261, 262, 264, 268, 270, 273, 276, 278, 284, 285, 288, 292-294, 298-301, 303-306
535B	AAE418, 419, 421, 423, 424, 428, 430-434, 441, 446, 448, 449
* Group 2 (no winch) *
525B	3KZ225, 233, 240, 265, 282, 286
535B	AAE401-410, 413, 415, 416, 422, 425, 426, 429, 435, 436, 439, 442, 443
* Group 3 (with winch) *
545	2FZ235, 250, 251, 253-262, 264-266, 268, 269, 272, 274, 276, 283-286, 288, 290, 292-295, 297, 298, 300, 301, 304, 311-315, 318, 322, 329, 334, 339, 342, 344
* Group 4 (no winch) *
545	2FZ236-241, 244-249, 252, 263, 267, 270, 273, 277-280, 303, 337, 345, 346, 356

PARTS NEEDED

***** Group 1 and 2 *****

1 ? 1257325 Hose
1 ? 1412940 Sensor
1 ? 1646871 Adapter
1 ? 1S0994 Clip
1 ? 2039165 Harness-As
1 ? 2076122 Wire As
1 ? 3E2337 Adapter
1 ? 3J1907 Seal-O-ring
1 ? 5P7854 Clip
4 ? 6V8397 Seal-O-ring
1 ? 6V8636 Connector-seal
2 ? 6V9850 Elbow-swivel
1 ? 8T4121 Washer-hard
1 ? 8T4136 Bolt
1 ? 9R3572 Boss (M12 X 1.75-6H THD)

***** Group 3 and 4 *****

1 ? 1087658 Hose
1 ? 1412940 Sensor
1 ? 1646871 Adapter
1 ? 1S0994 Clip
1 ? 2039165 Harness-As
1 ? 2076122 Wire As
1 ? 3E2337 Adapter
1 ? 3J1907 Seal-O-ring
1 ? 5P7854 Clip
5 ? 6V8397 Seal-O-ring
1 ? 6V8636 Connector-seal
2 ? 6V9850 Elbow-swivel
1 ? 8T4121 Washer-hard
1 ? 8T4136 Bolt
1 ? 8C8988 Elbow
1 ? 9R3572 Boss (M12 X 1.75-6H THD)

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
***Group 1 and 3 (Machines with winch)***
0-2500 / 0-24 months	100%	6.5	0	0	0	0
2501-3500 / 25-36 months	33 1/3%	3.3	0	0	50%	3.2
NOTE: This is a 6.5?hour job.
***Group 2 and 4 (Machines without winch)***
0-2500 / 0-24 months	100%	4.5	0	0	0	0
2501-3500 / 25-36 months	33 1/3%	2.3	0	0	50%	2.2
Note: This is a 4.5-hour job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Illustration 1
525B/535B Switch Location

Illustration 2
545 Switch Location

Remove the grapple control valve guard.
Remove the winch guards (if equipped with a winch).
Remove the fuel tank guard (if not equipped with a winch). Removing these guards will be necessary in order to route the hose and wire harness from the grapple control valve area to the hitch area.
Remove the auto-grab pressure switch from the hydraulic tube.

Illustration 3
Example is 545 with no winch

Install the hose and route to the center hitch area (Refer to Illustration 3).

Illustration 4

Install 2039165 Harness. Connect the single wire connector to the four-pin connector on the rear harness (normally used for the swing grapple).
Connect the two-pin connector to the two-pin connector that was connected to the pressure switch. On the 525B and 535B switch the yellow and black wires in this two pin connector so that they match up with the yellow and black wires on the new 2039165 Harness. (These wires should not need to be switched on the 545).

Note:

There have been a few incidents where the black and yellow wires were reversed at the power train control module. If the auto-grab system fails to operate after performing this procedure, try reversing the yellow and black wires.

Illustration 5 (545)

Illustration 6 (525B and 535B)

Attach the pressure sensor to the hose.
Weld the 9R3572 Boss in the general location shown in illustration 5 and 6 depending on the model of Skidder.
Connect the three-pin connector of the 2039165 Harness to the new pressure sensor (Illustration 5 & 6).
Attach the sensor to the 9R3572 Boss.
Secure wires where possible to prevent movement with tie wraps.
Remove the sheet metal located at the rear of the cab to gain access to the Grapple/Transmission electronic controller.
Move circuit E852 YL from J-1 connector pin 36 of the Grapple/Transmission control to J-2 connector pin 38 of the Grapple/Transmission control.

Illustration 7

At the grapple handle there are two unused two pin plugs on the harness. Plug them together by installing the 2076122 Wire Assembly (refer to Illustration 7) to get power to the rear. (This will connect circuit 165 YL to K934 GN. This will mean that the fuse operating this circuit is labeled DIFF LOCK-10A.)
Flash the Skidder with 231-3867 Flash File.
Perform the torque converter lock-up clutch calibration procedure. For more information on calibrating the torque converter lock-up clutch, refer to the power train testing and adjusting manual for the model of skidder being serviced.
Perform the auto-grab pressure sensor calibration procedure. For more information on calibrating the auto-grab pressure sensor, refer to Service Magazine; Media Number ? SEPD0663, Publication Date ? 2003/01/20, "New Software Provides Improvements and Enhancements". In the future, information on calibrating the auto-grab pressure sensor will also be available in the grapple testing and adjusting manual for the machine that is being serviced.

Note:

Software versions prior to 231-3867 did not have the feature of calibrating the auto-grab pressure control. The auto-grab system will work if the pressure sensor is not calibrated but there will be a fault code of 455-13. The auto-grab pressure sensor should be calibrated to better match the pressure setting of the hydraulic pump.