PRODUCT IMPROVEMENT PROGRAM REWORKING THE AIR INLET TO PREVENT HEATER RELAY FAILURES ON CERTAIN 311C, 312C, 314C, 315C, 318C, 320C AND 321C EXCAVATORS

Usage:

SEBE9085

February 28, 2005
U-63
A-46
D-53
O-54

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*Priority*	PRODUCT IMPROVEMENT PROGRAM REWORKING THE AIR INLET TO PREVENT HEATER RELAY FAILURES ON CERTAIN 311C, 312C, 314C, 315C, 318C, 320C AND 321C EXCAVATORS
1408, 1417		PI30720

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30720" 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 "PI30720" 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.

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COMPLETION DATE	TERMINATION DATE
August 31, 2005	February 28, 2006

PROBLEM

The air inlet needs to be reworked to prevent heater relay failures on certain 311C, 312C, 314C, 315C, 318C, 320C and 321C Excavators. The diode added to the engine air inlet heater relay circuit can cause some other components to fail. Most vulnerable are switch contacts. The diode can allow arcing between the contacts fusing them together. Contacts fused together cannot stop the constant flow of current to the heater relay and it overheats and burns. Removing the diode will eliminate this problem.

AFFECTED PRODUCT

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Model	Identification Number
*** Group 1 ***
311C	CKE1158-1272
314C LCR	PCA326-459
314C CR	KJA143-153
*** Group 2 ***
312C	FDS337-350
312C L	CBA1713-1960, 1962-1969, 1971-2021, 2025
315C	CJC1188-1504, 1506-1566, 1568-1578, 1580-1581, 1586-1588, 1592
318C	MDY263-336, 339-341 GPA268-313
320C	MAB404 PAB1755-2335, 2337-2413, 2415, 2417-2436, 2438-2502, 2504-2506, 2508-2541, 2543, 2445-2548, 2551, 2553, 2555, 2558, 2559, 2561-2563, 2565-2569, 2573, 2575, 2576, 2578-2581, 2584-2588, 2590, 2591, 2593, 2595, 2597, 2601-2603, 2605, 2611-2613, 2624, 2625, 2627, 2637, 2639, 2641 MAC292-295 PAC450-509, 511-513, 516-521, 523-525, 527, 530-531, 533
321C LCR	MCF276-386, 388

PARTS NEEDED

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Qty	Part Number	Description
*** Group 1 ***
1	1450549	Receptacle Assembly
*** Group 2 ***
1	3S2093	Strap ? Cable
1	7Y3953	Connector

ACTION REQUIRED

See the attached Rework Procedure.

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%	1	0	0	0	0
NOTE: This is a 1.0-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 - The Air Inlet Needs To Be Reworked To Prevent Heater Relay Failures

MODELS INVOLVED - 311C, 312C, 314C, 315C, 318C, 320C and 321C Excavators

Dear Caterpillar Product Owner:

The air inlet needs to be reworked to prevent heater relay failures on certain 311C, 312C, 314C, 315C, 318C, 320C and 321C Excavators. The diode added to the engine air inlet heater relay circuit can cause some other components to fail. Removing the diode will eliminate this problem. The diode needs to be removed 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 February 28, 2005 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 February 28, 2005 Service Letter

Rework Procedure

320C and 321C Removal Procedure

Please refer to the appropriate machine Service Manual. Review, understand, and adhere to all Safety and Environmental warnings and notices associated with servicing electrical circuits. Turn key switch to "OFF". Access electrical panel and turn main disconnect switch to "OFF". Remove panel cover to expose electrical circuits. For models 320C, 320CU, and 321C refer to the picture below for the approximate location of the diode to be removed within the electrical box.

Remove the diode in this manner (refer to the picture below):

Cut off vinyl tape, disconnect diode, and remove. (Wires to the DT connector leading to the diode are 310-Purple & 200-Black.) Install new connector and strap in this manner (refer to picture below):

Replace panel cover. Turn main disconnect switch to "ON" position if appropriate. Handle any parts disposition in accordance with your warranty bulletin on warranty parts handling.

Rework Procedure

311C, 312C, 312C L, 315C, 318C Diode Removal Procedure

Please refer to the appropriate machine Service Manual. Review, understand, and adhere to all Safety and Environmental warnings and notices associated with servicing electrical circuits. Turn key switch to "OFF". Access electrical panel and turn main disconnect switch to "OFF". Remove panel cover to expose electrical circuits. For models 311C, 312C, 312C L, 315C, and 318C refer to the picture below for the approximate location of the diode to be removed within the electrical box.

Remove the diode in this manner (refer to the picture below):

Cut off vinyl tape, disconnect diode, and remove. (Wires to the DT connector leading to the diode are 310-Purple & 200-Black.)

Install new connector and strap in this manner (refer to picture below):

Replace panel cover. Turn main disconnect switch to "ON" position if appropriate. Handle any parts disposition in accordance with your warranty bulletin on warranty parts handling.

Rework Procedure

314C Diode Removal Procedure

NOTE: Review the Instructions and Illustrations before starting rework.

Disassembly

Turn the engine start switch key to the "OFF" position.
Turn the battery disconnect switch to the "OFF" position. Remove the disconnect switch key.
Disconnect the battery cable at the battery disconnect switch.

NOTE: Do not allow the disconnected battery cable to contact the battery disconnect switch.

Disconnect the negative battery cable at the battery that is connected to the disconnect switch.
Remove the 096-5819 Tank As. Reserve by removing (2) 8T-4189 Bolts and (2) 8T-4224 Washers and 196-8174 Band-Support.

Rest reserve tank on air intake filter housing.

Remove 5I-8270 Battery Cover by removing (1) 8T-4133 Nut and (1) 8T-4121 Washer.
Remove 6W-6005 Hold Down-Battery, by removing (1) 8T-4133 Nut and (1) 8T-4121 Washer.

Remove (1) 3T-5760 Battery (Rear battery), (1) 8T-4133 Nut (located on underside of upper), and (1) 197-4333 Rod.

Remove (1) 3T-5760 Battery (Front battery).
Remove (2) 8T-4191 Bolts and (2) 8T-4121 Washers releasing the 193-3479 Panel Gp-Circuit Breaker from frame.

Ease the 193-3479 Panel Gp-Circuit Breaker forward and locate the 197-4385 Diode for the heater relay. Diode will have two wires connected ? 310 Purple and 200 Black.

NOTE: Confirm wiring ID number and color before removing diode, as several 197-4385 Diodes are used.

Remove Diode

Assembly

Replace diode with 145-0549 Receptacle Assembly.
Reattach 193-3479 Panel Gp-Circuit Breaker with (2) 8T-4191 Bolts and (2) 8T-4121 Washers. Torque bolts to 55 ± 10 Nm.
Insert (1) 3T-5760 Battery (Front Battery) into compartment.
Reattach 197-4333 Rod to bottom of compartment with 8T-4133 Nut. Torque nut to 55 ± 10 Nm.
Insert (1) 3T-5760 Battery (Rear Battery) into compartment.
Reassemble 6W-6005 Hold Down-Battery, secure with (1) 8T-4133 Nut and (1) 8T-4121 Washer. Torque nut to 55 ± 10 Nm.
Reassemble 5I-8270 Battery Cover, secure with (1) 8T-4133 Nut and (1) 8T-4121 Washer. Torque nut to 55 ± 10 Nm.
Reassemble 096-5819 Tank As. Reserve, secure with 196-8174 Band-Support, (2) 8T-4189 Bolts, and (2) 8T-4224 Washers. Torque bolts to 28 ± 7 Nm.
Reconnect the negative battery cable at the battery that is connected to the disconnect switch.