PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE WIRING HARNESS AND HARNESS SUPPORT BRACKET ON CERTAIN 311F, AND 313F GC EXCAVATORS WITH EXTENDED RUNNING HOURS (JAPAN EXCLUDED) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE WIRING HARNESS AND HARNESS SUPPORT BRACKET ON CERTAIN 311F, AND 313F GC EXCAVATORS WITH EXTENDED RUNNING HOURS (JAPAN EXCLUDED)

Usage:

TEBE5542-02

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12Jan2017

(Revised 02Mar2017)

U-30

D-21

O-24

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE WIRING HARNESS AND HARNESS SUPPORT BRACKET ON CERTAIN 311F, AND 313F GC EXCAVATORS WITH EXTENDED RUNNING HOURS (JAPAN EXCLUDED)
1408		PS45357

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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 "PS45357" 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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NOTE:	This Revised Service Letter replaces the 12Jan2017 (Revised 14Feb2017) Service Letter. A change has been made to the Action Required.

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TERMINATION DATE

31Jan2019

PROBLEM

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Certain 311F, and 313F Excavators have experienced intermittent black exhaust smoke and low engine power accompanied by error codes related to boost pressure sensor (102-20: "Engine intake manifold pressure sensor: Data drift").

Degradation of the performance of the internal connections within the engine harness interface connector may occur with extended hours due to vibrations. This can lead to the above-mentioned issue and symptoms.

A new harness support bracket 5170154/">517-0154 is an approved improved part which prevents the above failure mode by improving the installation of the harness interface connector.

AFFECTED PRODUCT

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Model	Identification Number
311FL	KCW00124-00129, 132-243, 245-275, 277-301, 304-344, 346-351, 355, 357-364, 366-369, 371-372, 374-375, 377, 379-381, 384, 386, 390-391, 393-398, 401-403, 405-409, 412-416, 419, 421-426, 429, 431-434, 436, 438, 441-442, 445, 447-448, 450-451, 453 LZF00178-00194, 196-297, 299-307, 309-371, 373-379, 381-382, 385-392, 394-400, 402-424, 426-443, 445-463, 465-478, 480-487, 489, 493, 497
313F LGC	GJD00176-00195, 197-198, 200-208, 210-215, 217-222, 224-273, 275-284, 286-312, 314-315, 317-326, 328-349, 351-363, 366-417, 420-427, 431-433, 435-436, 445, 447-449, 451-461, 463, 465-473, 475-494, 496-499, 501-504, 506-511, 513-530, 532-542, 544, 546-549, 551, 554-558, 560-562, 564, 568, 575, 585-586, 589-590, 592, 594-606 HDK00127-00130, 132-135, 137-140, 142-148, 152-158, 160, 162-167, 171, 173-176, 179, 181, 183-201, 203-212, 214-239, 243-245, 248-255, 257-263, 266, 268-269, 272-276, 278, 281, 283, 285, 287-288, 291, 293, 295-304, 306, 308-312, 316-329, 331, 334, 336-337, 341-346, 348-350, 353, 355-358, 360, 362-364, 366-370, 373-379, 382

PARTS NEEDED

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Qty	Part Number	Description
2	3169351	MOUNT-FIR TREE
1	3468219	FILM
1	5117010	HARNESS AS
1	5170154	BRACKET AS
1	5223733	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% 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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This service letter applies only to engines with more than 100 hours on service meter and not located in Japan.

If the engine has run for less than 100 hours, review for an other program for the engine wiring harness and apply if applicable.

Record the machine serial number, engine serial number, engine hours, engine wiring harness hours, and provide the information to your Dealer Technical Communicator (TC). Request the Dealer TC to submit the information to CPI number 359350 through CPI Feedback within the Service Information Management System (SIMSi).

Follow the attached Rework Procedure to replace the support bracket to the engine harness connector as well as the full engine harness assembly, including the extension lead to the remote engine ECM. Note that the counterweight needs to be removed to carry out this rework.

Please also refer to Service Magazine, M0080950 for information on the wiring harness design change and rework instructions.

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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%
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
2001-4000 hrs, 25-36 mo	33.0%	100.0%	0.0%	0.0%	50.0%	0.0%

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NOTE: This is a 5.6-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.

Rework Procedure

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Tooling Requirement:
No special tooling required
Wobble extension to tighten up M8 bolt recommended.

Rework instructions
1. Follow all safety guidelines and refer to SIS web for standard engine rework instructions. Prior to accessing and working on the engine, please make sure that the machine has been shut down for long enough and engine temperature allows for manual work. Ensure that the battery power has been switched off and key removed prior to performing the below rework instructions.

2. Remove counterweight as per instruction available in SIS web (KENR9856).

3. Disconnect the harnesses (511-7010 and 522-3733) by twisting the silver counterclockwise.

Image1.4.1

4. Remove x4 cap head M4 screws (456-5278) holding the engine wiring harness to the bracket.

Image1.5.1

5. Pull wiring harness (511-7010) across the C-section of the bracket and remove it from the bracket. Make note of the orientation of the connector within the bracket as the harness will need to be reinstalled with the same orientation.

Image1.6.1

Image1.6.2

6. Remove x1 M8 bolt holding the dipstick.
Note that in the 313F GC installation, further two M8 bolts will need to be removed to disconnect the breather hose support bracket from the harness bracket (456-4693).

Image1.7.1

Image1.7.2

7. Remove and keep x2 M8 bolts (124-3815) holding the bracket to the cylinder head.

Image1.8.1

Image1.8.2

8. Remove bracket (456-4693).

9. Sub-assemble x2 fir trees (316-9351) to the bracket (5170154/">517-0154).

10. Place the film (346-8219) on the top face of the new bracket (5170154/">517-0154) as illustrated in Image 1.11.1.

Image1.11.1

11. Remove the original engine harness (511-7010)
11.1. Disconnect wiring harness (511-7010) from all the sensors injectors and glow plugs.
Note: Most of the plugs have a lock on them and these will need to be ?unlocked? to allow the plug to be easily removed. See images below for some examples of the types of locks and ?locked/unlocked? position.

Image1.12.1

Image1.12.2

Image1.12.3

Image1.12.4

Image1.12.5

Image1.12.6

11.2. Cut the cable ties which hold the harness (511-7010) to the fir trees and remove as much of the wiring harness as possible.

11.3. The two clips which hold the two main portions of the engine wiring harness (511-7010) can easily be opened allowing the cable to be removed and they can remain in place and be used with the new harness assembly (511-7010).

Image1.14.1

Image1.14.2

11.4. The central rail of the wiring harness (511-7010) can be difficult to remove and will probably require the two tabs holding it to the bracket to be cut off either with the use of a blade or cutters.

Image1.15.1

Image1.15.2

11.5. Completely remove the wiring harness assembly (511-7010).

11.6. Ensure you remove all the fir trees left behind by un-screwing them from the holes.

12. Removing the original ECM lead harness (522-3733).
12.1. Similarly to the rework instructions of the engine-side harness assembly (511-7010) described in step 11, disconnect the wiring harness (511-7010) from any clipping point, cable tie and also disconnect the wiring harness from the ECM which is located in the cooling pack area of the machine.

12.2. Remove fully the original ECM lead harness (522-3733) from the machine installation. The first clipping point of this harness near the bottom section of the engine is expected to be re-usable.

13. Installing the new engine wiring harness assembly (511-7010).
13.1. Lay the new wiring harness assembly (511-7010) over the engine and locate the central rail onto the bracket and press it home so the clips fully engage.

13.2. Align the harness (511-7010) so the various branches are located in the correct slots in the two main clips on the top of the engine and close the clips to hold the loom securely.

13.3. Starting with the injectors, connect the plugs ensuring you connect them in the correct order, then connect the glow plugs. The glow plugs may require some force to push them on until you feel a positive click as it makes the correct connection.

13.4. Proceed to connect the remaining plugs to their respective sensors replicating the routing as shown in the image below and as per before the wiring harness (511-7010) was removed.

Image1.23.1

13.5. Once all connections are made begin locating the fir trees into their respective holes and brackets ensuring you fully press them in. Some work may be required moving the cable ties and fir trees along the wiring harness to ensure the harness assembly (511-7010) is correctly supported and not under any stress between clipping points.

14. Take new bracket (5170154/">517-0154) and install with existing bolts (124-3815). It is advisable to start engaging the left side bolt in the thread prior to installing the bracket and then use a wobble extension for better access to the bolt and tighten to the correct setting, i.e. 28+/-7 Nm.

Image1.25.1

Image1.25.2

15. Re-assemble dipstick holder to the bracket. Tighten to 28+/-7 Nm.
In the case of a 313F GC machine installation, also reinstall the breather hose support bracket with the two original M8 bolts and tighten to 28+/-7 Nm.

Image1.26.1

16. Reposition the harness connector through the C section of the bracket and remount to new bracket using the original x4 M4 bolts (456-5278). Tighten to 1.7+/-0.4 Nm.

Image1.27.1

Image1.27.2

17. Installing the new ECM-side wiring harness (522-3733)
17.1. Re-install the new ECM-side wiring harness (522-3733) as per previously installed.

17.2. Install cable ties where they had to be cut during the harness removal phase (ref. step 12).

18. Connect up the round plug connector of the ECM harness (522-3733) to the engine harness (511-7010). Make sure to keep the same orientation of the harness connector as before in order to minimise strain on the internal wiring.

Image1.30.1

19. Secure the ECM harness (522-3733) with the 2 fir tree clips on the bracket.
The reworked installation is illustrated in Image 1.31.3 for 311F models and in Image 1.31.4 for models 313F GC.