PRODUCT SUPPORT PROGRAM FOR REWORKING THE IGNITION CIRCUIT ON CERTAIN 568 FORESTRY EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE IGNITION CIRCUIT ON CERTAIN 568 FORESTRY EXCAVATORS

Usage:

TEBE3940-00

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11Jan2016

U-20

D-17

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE IGNITION CIRCUIT ON CERTAIN 568 FORESTRY EXCAVATORS
1417 1408 1416 7301		PS44957

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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 either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44957" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

31Jan2018

PROBLEM

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The existing circuit can cause chatter on the ignition circuit on certain 568 Forestry Excavators. If the existing circuit is not reworked it can generate 3241-4 / 3242-4 (J1939), and 3485-4 / 2452-4 (CDL) Flame detect sensor and DPF inlet temp sensor diagnostics. It also could lead to premature ignition switch failure.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
568	YJX00100-00124
568 LL	BRB00200-00326

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*****Group 2*****
568	YJX00125-00137
568 LL	BRB00327-00374

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
10	5P5623	WIRE-ELECTRICAL
1	9X3402	SOCKET-CONNECTOR
1	2552752	SWITCH AS-START
1	4751722	WIRE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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	2552752	SWITCH AS-START
1	4751722	WIRE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 2.0-hour job for Group 1

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
4001-8000 hrs, 25-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 1.5-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

Group Number 1

IMPORTANT: Ensure that the machine electrical system is isolated. Refer to the Operation and Maintenance Manual for additional safety information before completing this Rework Procedure.

1. Remove and replace the key switch.

2. Locate the two power convertors. The power convertors are bolted underneath the cab. Refer to Image1.1.1.

Image1.1.1

3. Remove the 308 YL 24V supply from pin 2 of the convertor designated as (128) on the schematic in SIS Web.

4. Splice into the 127 OR for the air seat and run a wire to pin 2 of the convertor as a new 24V supply to the convertor. Use a length of 5P-5623 Bulk Wire using a 9X-3402 Electrical Socket.

5. Locate the 15AMP HVAC circuit breaker on the wiring control panel in the battery compartment.

6. Remove wire 308 YL from the 15AMP HVAC circuit breaker in the circuit breaker panel. Tape it and tie it back to the harness with a strap.

Image1.2.1

7. Connect the 475-1722 Jumper Wire between the circuit breaker (where the 308 YL used to be connected).

8. Remove the screw holding the 112 purple wire on the main relay.

9. Connect the other end of the jumper wire and replace 112 PU and retighten the screw.

Image1.3.1

Group Number 2

IMPORTANT: Ensure that the machine electrical system is isolated. Refer to the Operation and Maintenance Manual for additional safety information before completing this Rework Procedure.

1. Remove and replace the key switch.

2. Locate the 15AMP HVAC circuit breaker on the wiring control panel in the battery compartment.

3. Remove wire 308 YL from the 15AMP HVAC circuit breaker in the circuit breaker panel. Tape it and tie it back to the harness with a strap.

Image2.1.1

4. Connect the 475-1722 Jumper Wire between the circuit breaker (where the 308 YL used to be connected).

5. Remove screw holding the 112 PU wire on the main relay.

6. Connect the other end of the jumper wire and replace 112 purple and retighten the screw.