PRODUCT IMPROVEMENT PROGRAM FOR AIR CONDITIONER REWORK ON CERTAIN 322C, 322C L, 325C, 325C L, 330C, AND 330C L EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR AIR CONDITIONER REWORK ON CERTAIN 322C, 322C L, 325C, 325C L, 330C, AND 330C L EXCAVATORS

Usage:

SEBE8081-02

July 26, 2002
(Revised September 2002)
U-182
A-129

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR AIR CONDITIONER REWORK ON CERTAIN 322C, 322C L, 325C, 325C L, 330C, AND 330C L EXCAVATORS
7337, 1809, 7320		PI30372

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30372" 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 "PI30372" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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 July 26, 2002 (Revised August 2002) Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
January 31, 2003	July 31, 2003

PROBLEM

The A/C system provides inadequate cooling on certain 322C, 322C L, 325C, 325C L, 330C, 330C L. The rework consists of flashing the controller, checking for proper charge and recharging if necessary, replacing cam, and removing top seal.

AFFECTED PRODUCT

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Model	Identification Number
322C	CAM1-132 CBY1-204
322C L	BKJ1-668 BPH1-226
325C	G1L1-214 M2K1-298 S3M1-317 Y4P1-393
325C L	BFE1-412
330C L	DKY1-639

PARTS NEEDED

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Qty	Part Number	Description
1	2202017	Cam

ACTION REQUIRED

See the attached Rework Procedure. Also refer to TIBU3649 (Certain operating conditions may cause the air conditioner evaporator to freeze up). For Recharge and seal removal also see the TIBU3649.

OWNER NOTIFICATION

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%	4.0	0	0	0	0
NOTE: This is a 4.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

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.

Attach. (1-Owner Notification)
(2-Rework Procedure)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR PROGRAMMING THE AIR CONDITIONER CONTROLLER

MODELS INVOLVED ? CERTAIN 322C, 322C L, 325C, 325C L, 330C, AND 330C L EXCAVATORS

Dear Caterpillar Product Owner:

Operating conditions may cause the air conditioner evaporator to freeze up on the products listed below. 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 July 26, 2002 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to July 26, 2002 Service Letter

Rework Procedure

Air Conditioner Controller Reprogramming Tool

To reprogram the A/C controller use the following procedure:

Remove the 1684605 control panel and unplug the 4 pin DT harness connector (see control panel removal).
Plug the 4 pin DT harness connector from the control panel into the reprogram tool.
Turn the machine electrical power on (KEY ON).
The reprogramming tool will power up the A/C controller and blower fan. Reprogram the controller and shut off. The time required will be less than 15 seconds.
Turn the machine electrical power off (Key OFF).
Unplug reprogram tool and reconnect control panel to 4 pin DT harness connector, and reinstall control panel.
Turn the machine electrical power on (Key ON).
With the control panel display ON go into parameter mode (see accessing parameter mode).
Check reprogram parameter are correct for 08P, 10P, and 11P. Degrees F values are 36; -04; -04. Degrees C values are 2.0; -2.0; -2.0; respectively.
Clear all logged errors (see clearing error memory).
Reprogramming procedure complete.

Control Panel Removal

Insert flat blade screwdriver into slot to release spring loaded clips on each end. Do not force panel out of opening, panel will remove easily when clips are released.

NOTE: Short length of harness to control panel may require the use of screwdriver to release retainer clip on the electrical DT connector.

Accessing Parameter Mode

With the control panel display ON multiple keys must be pressed simultaneously: press and hold down the AUT button, then push the fan speed knob down. This will put you in parameter mode, scroll from P00 to P20, & P36 by rotating the fan speed knob. To exit parameter mode push the AUT button.

Clearing Error Memory

To clear the ATC error memory of any stored errors use the following procedure:

Turn the machine key ON.
Turn the control panel OFF, push down on fan control knob to turn off.
With the control panel display OFF multiple keys must be pressed simultaneously to enter error check mode.
Press and hold down fan speed knob, within two seconds push temperature control knob.
This will put you in error retrieval mode, the display will flash between 01E and the error value, i.e.: 000; 008; 128.
Push fan speed knob, this will clear error memory and put ATC back into normal operation mode.

English versus Metric Units Toggle

The temperature can be displayed in either English or Metric units. With the control panel display ON multiple keys must be pressed simultaneously. Press and hold down the AUT button, then push the temperature control knob down. This will toggle the display between Degrees Fahrenheit and Degrees Celsius.

2202017 Cam Replacement

Remove the lunch box. Four bolts at rear window and 2 inside lunch box.
Unplug the wiring for the two 12v power adapters.
Remove the lower cover below the lunch box two bolts.

For proper alignment of actuator and cam, override automatic mode and change to floor mode.

Illustration 1 (Floor and Delivery)

Illustration 2 (Rear Duct Removal)

Air Delivery Mode Box Removal

Remove air temp sensor.
Disconnect electrical connector from mode actuator.
Disconnect electrical connector (A) and (B). This will aid in removal of mode box.
Cut harness strap from bracket on mode box.
Remove four screws mounting mode box to conditioner box (C) and (D).
Disconnect ducts(floor, face, and defrost) using a screwdriver to pry duct over tabs (see duct connections photo).

Illustration 3

Illustration 4 (Duct Connections)

Illustration 5 (Disconnect Ducts)

: Illustration 6

Illustration 7 (Removal of Cam Cover)

Illustration 8 (Cam Before Removal)

New Cam Assembly Procedure

With lever (A) and gear (B) timed (should not have to remove lever and gear).
Insert 220-2017 cam trace into pin of lever (A) this is a blind assembly, push cam completely into place.

NOTE: If cam is not completely seated pin on lever(A) can jump out of trace.

Time lever (C) and gear (D) and insert pin on lever (C) into trace (E).
Time lever (F) and gear (G) and insert pin on lever (F) into trace (H).
Install cam cover and four screws.
Rotate shaft on cam to make sure all door are functioning properly.
Rotate flats on shaft of cam to align with flats in actuator and install actuator to mode box with three screws.

Illustration 9 (New Cam Installed)

Illustration 10 (Assembly of Actuator)

Air Delivery Mode Box Installation

Connect floor, face, and defrost ducts to mode box, make sure tabs are in slots of ducts.
Mounting mode box to conditioner box with screws C and D.
Connect electrical connector for mode actuator, connectors A and B, and install temp sensor. Add strap for harness to bracket.
Power up conditioner unit and using air deliver mode button on panel, check to make sure all air delivery modes are functioning properly.

NOTE: A small amount of air bypass of closed doors is normal.