PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WIRING HARNESS FOR THE ENGINE AIR HEATER RELAY ON CERTAIN 320D, 320D L, AND 323D LN EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WIRING HARNESS FOR THE ENGINE AIR HEATER RELAY ON CERTAIN 320D, 320D L, AND 323D LN EXCAVATORS

Usage:

REBE2171-01

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27Jul2007

(Revised 28Aug2007)

U-364

A-300

D-301

O-324

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WIRING HARNESS FOR THE ENGINE AIR HEATER RELAY ON CERTAIN 320D, 320D L, AND 323D LN EXCAVATORS
1090 1058 1408		PI10616

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10616" 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 "PI10616" 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:	This Revised Service Letter replaces the 27Jul2007 Service Letter. Changes have been made to the Affected Product of 320D OEM machines.

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PROBLEM

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The wiring harness for the engine air inlet heater relay needs to be reworked on certain 320D, 320D L and 323D LN Excavators. A new harness will be added to eliminate the possibility of the air inlet heater relay remaining closed, which could result in the heater staying on and overheating. If the relay overheats, this may possibly cause a fire, which may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
320D	FAL00183, 185, 189, 191-192, 194, 196, 199-200 KGF00106-00133, 135-151, 153-178, 180-185, 187, 190-191, 193-195, 197-199, 201-213, 217-236, 239-260, 262, 264-268, 270, 272-274, 276-283, 285-286, 290-291, 294-298 PHX00198-00212, 214-305, 308-311, 313-314, 316-340, 345, 351-380, 382-384, 386-390, 392, 396, 398-406, 408-410, 414, 416-420, 422-423, 425, 427, 430, 432-433, 435-436, 439-443, 445-447, 449-456, 458, 460-467, 472-486, 488-493, 495, 497-506, 510, 513, 516, 518-520, 522, 549
320D (OEM)	GPX00300-00307
323D LN	RAC00255

PARTS NEEDED

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Qty	Part Number	Description
2	3S2093	STRAP-CABLE
1	1160118	CLIP
1	3068691	HARNESS AS

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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

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 1.0-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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WIRING HARNESS FOR THE ENGINE AIR HEATER RELAY

MODELS INVOLVED - 320D, 320DL, and 323D LN Excavators

Dear Caterpillar Product Owner:

The wiring harness of the engine air inlet heater relay needs to be reworked on the products listed below. A new harness will be added to eliminate the possibility of the air inlet heater relay remaining closed, which could result in the heater staying on and overheating. If the relay overheats, this may possibly cause a fire, which may result in personal injury or death. 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 27Jul2007 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 27Jul2007 Service Letter

Rework Procedure

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1. Locate the machine at rework area and position the front linkage on the ground.

2. Turn the engine key off and leave the hydraulic lock lever in the locked position.

3. Open the engine hood cover.

4. Pull out connector-A of current wiring harness from heater relay of engine.

Image1.4.1

5. Loosen the bolt of harness clip, and re-tighten the bolt to a torque of 55 +/- 10 Nm together with previous clip and additional 116-0118 Clip.

Image1.5.1

6. Connect rework harness with heater relay connector.

Image1.6.1

7. Fix connector with diode of rework harness with additional clip.

Image1.7.1

8. Connect rework harness with connector-A, and fix them with 3S-2093 Strap.

Image1.8.1

9. Check the supply voltage to heater by voltmeter.

9.-(1) Turn over the vinyl cap in the upper part of heater.

Image1.10.1

9.-(2) Set the terminal of voltmeter. Mode is DC voltage.

Image1.11.1

9.-(3) Measure the voltage one second after turned engine key ON. The correct voltage range is from 21.6 V to 24.0 V.

9.-(4) Confirm the voltage should be 0(Zero) roughly 3 seconds after turning the engine key ON. Refer to the timing chart of heater operation.

9.-(5) If the voltage is not following the "Heater operation timing chart", please do the following trouble shooting of step-11.

Image1.14.1

10. Return the vinyl cap to original position.

11. If you can not get the correct voltage range of 21.6 to 24V, please exchange with other new harness. If voltage did not become zero, please exchange with new ADEM.
After exchanging, please measure the voltage again from step of 9.-(3).