PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING UPDATED MACHINE SYSTEM AND GRADE CONTROL SOFTWARE AND REPLACING THE 481-8148 VALVE GP FOR WATER SYSTEM PUMP ON CERTAIN PM620 AND PM622 COLD PLANERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING UPDATED MACHINE SYSTEM AND GRADE CONTROL SOFTWARE AND REPLACING THE 481-8148 VALVE GP FOR WATER SYSTEM PUMP ON CERTAIN PM620 AND PM622 COLD PLANERS

Usage:

TEBE6697-01

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18Dec2017

(Revised 10Jan2018)

U-719

A-507

D-606

O-600

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING UPDATED MACHINE SYSTEM AND GRADE CONTROL SOFTWARE AND REPLACING THE 481-8148 VALVE GP FOR WATER SYSTEM PUMP ON CERTAIN PM620 AND PM622 COLD PLANERS
5614		PI32831

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32831" 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 "PI32831" 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:

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.

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NOTE:	This Revised Service Letter replaces the 18Dec2017 Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
30Jun2018	31Dec2018

PROBLEM

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The performance of the water spray pump can be improved by replacing the existing 481-8148 Valve GP and installing the updated 5232294/">523-2294 Transmission Software. The new 5290219/">529-0219 Valve GP and the 5232294/">523-2294 Transmission Software will remove water spray system instability and improve water spray pump efficiency. Additional planned software updates, unrelated to this issue, are available for the other machine ECMs and will be installed in conjunction with this update.(See Software release notes for details)

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
PM620 HRC	JB900100-00141, 161, 164
PM620 LRC	LH900100-00113, 129
PM622 HRC	JFC00101-00133, 163
PM622 LRC	JCF00100

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*****Group 2*****
PM620 HRC	JB900142-00159
PM620 LRC	LH900114-00124
PM622 HRC	JFC00134-00153
PM622 LRC	JCF00101

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*****Group 3*****
PM620 HRC	JB900160
PM620 LRC	LH900125-00128
PM622 HRC	JFC00154-00157, 159

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2M9780	SEAL-O-RING-STOR
1	3K0360	SEAL-O-RING
3	6V8398	SEAL-O-RING-ORFS
1	7J9108	SEAL-O-RING-ORFS
1	8T8737	PLUG-SEAL
1	5192253	SFWR GP-A2008
1	5192255	SFWR GP-A3000
1	5232294	SFWR GP-A5000
1	5232308	SFWR GP-A4030
1	5250903	WIRE AS
1	5287247	SFWR GP-A3017
1	5290219	VALVE GP-BANK 2
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	2M9780	SEAL-O-RING-STOR
1	3K0360	SEAL-O-RING
3	6V8398	SEAL-O-RING-ORFS
1	7J9108	SEAL-O-RING-ORFS
1	8T8737	PLUG-SEAL
1	5192253	SFWR GP-A2008
1	5192255	SFWR GP-A3000
1	5232294	SFWR GP-A5000
1	5232308	SFWR GP-A4030
1	5287247	SFWR GP-A3017
1	5290219	VALVE GP-BANK 2
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	2M9780	SEAL-O-RING-STOR
1	3K0360	SEAL-O-RING
3	6V8398	SEAL-O-RING-ORFS
1	7J9108	SEAL-O-RING-ORFS
1	5192253	SFWR GP-A2008
1	5192255	SFWR GP-A3000
1	5232294	SFWR GP-A5000
1	5232308	SFWR GP-A4030
1	5287247	SFWR GP-A3017
1	5290219	VALVE GP-BANK 2
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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Note: Always use the latest software available. Sometimes the flash file part numbers are updated before the program terminates.

UPDATE MACHINE SYSTEMS SOFTWARE (All Groups)

Flash the 519-2255, 519-2253, 5232294/">523-2294 Software into the respective Machine, Steering and Transmission ECMs using Cat ET.

Note: The 5232294/">523-2294 Software improves the water spray system control and performance with improved water pressure control parameters.

Note: After 5232294/">523-2294 Software is installed the 5290219/">529-0219 Valve GP must be installed on the water spray pump motor (Per rework procedure "Install Water Spray System Control Valve Manifold" listed on this letter) prior to operating in order to avoid over speed of the pump while running dry.

Note: In order to complete the machine configuration changes, Cat ET 2016B or higher is needed.

See release notes for a list of improvements and issue resolutions included in each software update.

UPDATE DISPLAY SOFTWARE (All Groups)

Connect all removable displays to the machine.

Flash the 523-2308 Software into the machine displays via Ethernet using Winflash.

Note: Make sure you do not have an active VPN connection when connecting to the machine Ethernet as this may hinder communication with the machine network and prevent the flash from occurring.

See release notes for a list of improvements and issue resolutions included in each software update.

REVIEW CONFIGURATION OF INSTALLED OPTIONS (All Groups)

The Dust Collector System Installation status needs to be set. Within ET access the configuration screens by pressing F5 (or click Service, Configuration menus.) Select the Machine Control ECM. Select Machine Configuration. Set the status for the Dust Collector System per the actual machine configuration. Requires Cat ET 2016B or higher.

Similarly, review the status of the Truck Lights (Machine Control ECM Machine Configuration), Inboard Ski (Steering Control ECM Grade Control) and folding conveyor and set as per the actual machine configuration.

REVIEW SOFTWARE RELEASE NOTES FOR DESCRIPTIONS OF OTHER CHANGES.

UPDATE GRADE CONTROL SOFTWARE (All Groups)

Load the 528-7247 Software on to a USB 2.0 compatible USB jump drive.

Note: Make sure there are no other versions of software on the root (top) directory of the jump drive - move all other software files into another folder or delete them.

Install the USB jump drive in to the machine USB port located in the center operator console.

Enter the Grade Control system using the MAIN center display. If equipped with double center displays, the main display is the left display.

Click the Menus icon in the upper right corner of the screen.
Click the Installation Menu.
Heed the caution notice and click OK.
Click the Firmware Upgrade menu.
Select from USB. Note: Do NOT select Local.
Select the file.
Allow the flash to proceed.
Remove the jump drive when the flash process is complete.

Note: The new Cat Grade and Slope software improves the finish of the cut with improved control method.
A new feature is also available:
GRADE AND SLOPE DISPLAY ARROWS CONFIGURATIONS (See Images from 1 through 3)
"Display Arrows" setting is used to change the function of the raise / lower soft keys in the MANUAL mode. There are two settings:
-Manual Leg Movement: Display arrows raise or lower front legs.
-Manual Target Adjustment: Display Arrows change the desire depth (Target Value). Explain this new option to the owner.

GRADE AND SLOPE CROSS COUPLING ADJUSMENT (See Images from 4 through 6)
NOTE: Adjust the front to rear coupling to about 70% to ensure the machine come down evenly when plunging.

FOLLOW AND COMPLETE RESPECTIVE REWORK INSTRUCTIONS FOR EACH OF THE GROUPS.

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Image1

Image2

Image3

Image4

Image5

Image6

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 5.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.5-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 4.0-hour job for Group 3

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING UPDATED MACHINE SYSTEM AND GRADE CONTROL SOFTWARE AND REPLACING THE 481-8148 VALVE GP FOR WATER SYSTEM PUMP

MODELS INVOLVED - CERTAIN PM620 AND PM622 COLD PLANERS

Dear Cat Product Owner:

The Machine System and Grade Control Software needs to be updated and the Water Spray Pump Control Valve needs to be replaced on the products listed below. These updates will improve the Water Spray Pump performance and Grade Control performance. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 18Dec2017 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 18Dec2017 Service Letter

Rework Procedure

Machine Preparation

1. Clear all personnel from the machine and from the area around the machine.
2. Start the Engine, Park the machine on a hard, level surface.
3. Center the second stage conveyor.
4. Lower the front and raise the rear of the machine, maintain minimum clearance between the rotor bids and the ground.
5. Turn Engine start switch to OFF position.
6. Turn the battery disconnect switch to the OFF position.
7. Attach a ?Do not Operate? warning tag to the start switch before you service the equipment.

GROUP 1
DONGLE INSTALLED ON MACHINES WIHTOUT CONVEYOR SWING OPTION

REQUIRE PARTS:

Image1.1.1

Image1.1.2

Locate the conveyor release swing sensor connector LH-C76.
Remove existing connector.

Image1.2.1

Install the new connector (P) to the machine harness.

GROUP 3
STEERING ECM CONNECTOR REWORK

REQUIRE PARTS:

Image1.3.1

Image1.3.2

Open electrical compartment access door (S).
Remove bolt (y) and Pin (X).
Swing the electronic board (T) open.

Image1.4.1

Locate Steering ECM (Z).
Disconnect connector (J1) and pull pin 37 off the connector.
NOTE: If Pin 37 is not present skip this step and proceed to install connector (J1) on steering ECM (Z).
Cover pin with non adhesive heat shrink.
Install plug - seal (O) in location 37 of connector (J1).
Install connector (J1) on steering ECM (Z).
Swing the electronic board (T) back to its original position.
Install Bolt (Y) and Pin (X).
Close Electrical compartment access door (S).

GROUP 1, 2 and 3
NEW WATER SPRAY SYSTEM CONTROL VALVE MANIFOLD INSTALLATION

Note: This new manifold will limit max flow rate to motor when water tank is empty and pump is still running.

REQUIRE PARTS:

Image1.6.1

Image1.6.2

Remove Bolts (A) and Low pressure water spray pump access cover (B).

Image1.7.1

Image1.7.2

Locate Valve manifold (C) attached to the motor (D) on the low pressure water spray pump (E).
Disconnect the two hydraulic hoses (F) from port P and T of the valve manifold (C).
Disconnect electrical harness (G) from solenoid (H).

Image1.8.1

Remove the four bolts (J) located on the front of the water spray valve manifold.
Remove the water spray valve manifold (C) from the motor (D).

Image1.9.1

Remove adapters (L) from ports P and T on old valve manifold (C).
Remove plugs (N) and (O) from their respective ports on the New valve manifold (M).

Image1.10.1

Image1.10.2

Install adapters (L) with their respective new O-rings (R)(U)(V)(W) in ports P and T of the New valve manifold (M).
Install new O-rings (R) in ports (S) on the New valve manifold (M).

Image1.11.1

Install the new valve manifold (M) on motor (D) using previously removed four bolts (J).
Torque bolts (J) to 23 Nm.

Image1.12.1

Connect the two hydraulic hoses (F) to ports P and T.
Connect the electrical harness (G) to solenoid (H).

Image1.13.1

Test Procedure:

Ensure there is water in the machine water tank.
Turn the battery disconnect switch to the ON position.
Turn engine start switch to the ON position to start the engine.
Turn ON low pressure water spray system.
Check water spray system gauge indicator, it should be 5.5 bars +/- 0.5 at 100% command (all LEDs illuminated) with any or all spray bars on.
Turn Low pressure water spray system ON and OFF several times to check for normal operation.
Install water spray pump low pressure access over (B) with four bolts (A).