PRODUCT IMPROVEMENT PROGRAM FOR THE REWORKING AND REPLACING THE ENGINE INTERFACE HARNESS 481-5636 ON CERTAIN C2.2 INDUSTRIAL ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR THE REWORKING AND REPLACING THE ENGINE INTERFACE HARNESS 481-5636 ON CERTAIN C2.2 INDUSTRIAL ENGINES

Usage:

TEBE7234-00

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27Feb2018

U-117

O-110

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR THE REWORKING AND REPLACING THE ENGINE INTERFACE HARNESS 481-5636 ON CERTAIN C2.2 INDUSTRIAL ENGINES
1408 1000		PI11137

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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 "PI11137" 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 "PI11137" 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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PROBLEM

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The engine interface harness needs to be inspected on certain C2.2 Industrial Engines. It has been identified that the wiring schematic that may have been used to manufacture the harness had an error that can lead to the fuel pump and starter motor energizing (if the main power feeds/grounds to the ECM are disconnected, but the key switch is ON) causing the engine to start cranking. This may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
C2.2	G4300262-00263, 268-275, 308, 314-335, 337-352, 356-373, 375, 377-378, 383-393, 395-396, 402, 405-406 J2600251, 258

PARTS NEEDED

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Qty	Part Number	Description
2	3S2093	STRAP-CABLE
1	7T0094	SOCKET-CONNECTOR
1	5244094	HARNESS AS
4	BULK_WIRE	RED 14AWG (4DM)
1	HEAT_SRINK_TUBE	HEAT SHRINK TUBE
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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Important Safety Information:

Work safely.
Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards, including human factors that can affect safety. This person should also have the necessary training, skills and tools to perform these functions properly.

Follow safety precautions and warnings are provided in this instruction, on the product and in the product?s Operation and maintenance manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
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If the engine is installed into a machine, read and understand the OEM?s operating instructions.

Wear the correct protective equipment as required. Refer to the relevant OMM for more information.
The engine must be cold with the cooling system depressurised, isolated electrically before and while the rework is performed. All fluid supply system to the engine must be isolated. Follow the proper lockout tag out procedures to protect against the unexpected energizing or start-up of the engine. Failure to follow these warnings could result in injury to personnel during service. Attach a ?Do Not Operate? warning tag to the machine start key switch or controls before performing any service to the machine. Refer to the relevant OMM for more information.

To remove Engine Interface Harness;

1 Disconnect the engine interface harness by unclipping 58 way plug from engine ECM and 31 way connect from machine side harness, and the other smaller connectors.

2 If necessary remove any cable ties securing engine interface harness, to brackets or clips.

3 Remove engine interface harness 481-5635

4 Remove the key-switch signal wire from position 8 from within the machine interface (31-way) connector-signals as described below. Image:1

6 Remove the socket terminal from the key-switch signal wire, then add an additional length of 2mm thick wire, so that the wire is long enough to reach the machine power interface connector ~400mm, by soldering to the end. Cover solder with a protective glue lined heat shrink sheath. Crimp a new socket terminal 7T-0094 to the end of the additional length of wire. Insert the new socket terminal into the machine interface power connector (8-way) position B, as described below. Image2:

7 Confirm continuity between each end of the key-switch signal wire on the machine harness.

8 Install new engine interface harness 524-4094

9 Install new cable ties if necessary

10 Re-Connect the 58 way plug from engine ECM and 31 way connect from machine harness and the 8 way power connector, and all other smaller connectors.

11 Re-Connect all fluid supply systems to the engine.

12 Re-Connect all electrical supplies system to the engine and the control systems.

13 Start the engine, Refer to the OMM for the correct procedure.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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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 2.0-hour job

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PARTS DISPOSITION

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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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING AND REPLACING THE ENGINE INTERFACE HARNESS 481-5636 ON CERTAIN C2.2 ENGINES.

MODELS INVOLVED - (G43 - J26)

Dear Cat Product Owner:

The engine interface harness needs to be inspected and possibly reworked on the products listed below. The existing engine interface harness could be incorrectly wired by the supplier. 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.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 27Feb2018 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 27Feb2018 Service Letter