PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND POSSIBLE REPAIR OR REPLACEMENT OF CERTAIN WIRING HARNESSES AND AIR CONDITIONING SWITCH ON CERTAIN 525C, 535C, AND 545C WHEEL-TYPE SKIDDERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND POSSIBLE REPAIR OR REPLACEMENT OF CERTAIN WIRING HARNESSES AND AIR CONDITIONING SWITCH ON CERTAIN 525C, 535C, AND 545C WHEEL-TYPE SKIDDERS

Usage:

REBE2731-00

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12Feb2008

U-70

A-58

D-55

O-63

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND POSSIBLE REPAIR OR REPLACEMENT OF CERTAIN WIRING HARNESSES AND AIR CONDITIONING SWITCH ON CERTAIN 525C, 535C, AND 545C WHEEL-TYPE SKIDDERS
1403 1408 1435 7320		PI31448

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31448" 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 "PI31448" 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:

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
31Aug2008	28Feb2009

PROBLEM

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The electrical connectors located at the chassis to engine harness interface and chassis to cab harness interface need to be inspected for signs of corrosion on the electrical contacts. Depending on the extent of the corrosion, a jumper repair harness may need to be installed at the cab/chassis interface and/or engine to chassis interface. Corrosion in the connectors can result in intermittent operation of the electrical system or unexpected down time. Machines in Group 2 also require a new air conditioning (A/C) pressure switch to address a quality issue with the existing switch.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
525C	52500096-00246
535C	53500198-00231
545C	54500298-00326

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*****Group 2*****
525C	52500247-00414
535C	53500232-00275
545C	54500327-00380

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	3C3364	NUT-HALF M8
4	3E5226	SOCKET-CONN
1	6V8188	NUT-FULL
5	7K1181	STRAP-CABLE
1	8T4195	BOLT
50	9X3401	PIN-CONNECTOR
50	9X3402	SOCKET-CONNECTOR
4	1153519	PIN-CONNECTOR
1	1257876	TUBE-SEALED
2	1261767	PIN-CONNECTOR
2	1261768	SOCKET-CONNECTOR
2	1325789	CLIP-LADDER
1	1344540	HOSE-SLEEVE
1	2048000	MOUNT-TIE WRAP
1	3021523	HARNESS AS
1	3153231	HARNESS AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an inital 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*****
2	3C3364	NUT-HALF M8
4	3E5226	SOCKET-CONN
1	6V8188	NUT-FULL
5	7K1181	STRAP-CABLE
1	8T4195	BOLT
50	9X3401	PIN-CONNECTOR
50	9X3402	SOCKET-CONNECTOR
1	1145333	SWITCH AS-PRESS
4	1153519	PIN-CONNECTOR
1	1257876	TUBE-SEALED
2	1261767	PIN-CONNECTOR
2	1261768	SOCKET-CONNECTOR
2	1325789	CLIP-LADDER
1	1344540	HOSE-SLEEVE
1	2048000	MOUNT-TIE WRAP
1	3021523	HARNESS AS
1	3153231	HARNESS AS
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an inital 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 appropriate Service Manual as necessary.

Group 1:
Inspect Harnesses.

Inspection of engine to chassis harness connectors:

1. Locate the connectors, unmate them, and inspect for signs of contact corrosion. Refer to Image3 for examples of connector contact corrosion at the chassis to engine harness connection.

2. If no corrosion is noted, install a 27 cm piece of 134-4540 hose and two 7K-1181 cable straps as shown in Image1 and Image2. Make sure that the hose does not contact the tube assembly.

3. If corrosion is noted, refer to special instruction REHS3696, "525C, 535C and 545C Harness Repair for Corrosion"

Inspection of the chassis to cab connectors:

1. Refer to image 7 for location of connectors, unmate them, and inspect for signs of corrosion. Refer to Image4 and Image5 for typical corrosion. If no corrosion is noted, remate the connectors.

2. If corrosion is noted, follow the special instruction, REHS3696, "525C, 535C and 545C Harness Repair for Corrosion" for inspection and repair/replacement of the affected harnesses.

Group 2:
Inspect Harnesses and Replace A/C switch.

Inspection of engine to chassis harness connectors:

1. Locate the connectors, unmate them, and inspect for signs of contact corrosion. Refer to Image3 for examples of connector contact corrosion at the chassis to engine harness connection.

2. If no corrosion is noted, install a 27 cm piece of 134-4540 hose and two 7K-1181 cable straps as shown in Image1 and Image2. Make sure that the hose does not contact the tube assembly.

3. If corrosion is noted, refer to special instruction REHS3696, "525C, 535C and 545C Harness Repair for Corrosion"

Inspection of the chassis to cab connectors:

1. Refer to image 7 for location of connectors, unmate them, and inspect for signs of corrosion. Refer to Image4 and Image5 for typical corrosion. If no corrosion is noted, remate the connectors.

2. If corrosion is noted, follow the special instruction, REHS3696, "525C, 535C and 545C Harness Repair for Corrosion" for inspection and repair/replacement of the affected harnesses.

Replacement of A/C pressure switch:

1. For machines listed in group 2, replace the A/C pressure switch. Refer to Image6 for location of the switch.

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Image1

Image2

Image3

Image4

Image5

Image6

Image7

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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 1
1.0 hour Service Claims allowance is provided to cover harness inspection and boot installation. NOTE: Dealer to perform the most economical repair based on the results of the inspection. An additional 2.5 hours will be allowed to install the 302-1523 cab/chassis jumper harness. An additional 5 hours will be allowed to install the 315-3231 engine/chassis jumper harness.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 2
1.5 hour Service Claims allowance is provided to cover harness inspection, boot installation, and A/C pressure switch installation. NOTE: Dealer to perform the most economical repair based on the results of the inspection. An additional 2.5 hours will be allowed to install the 302-1523 cab/chassis jumper harness. An additional 5 hours will be allowed to install the 315-3231 engine/chassis jumper harness.

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.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION AND POSSIBLE REPAIR OR REPLACEMENT OF CERTAIN WIRING HARNESSES AND AIR CONDITIONING SWITCH ON CERTAIN 525C, 535C, 545C WHEEL-TYPE SKIDDERS

MODELS INVOLVED - 525C, 535C, and 545C Wheel-Type Skidders

Dear Caterpillar Product Owner:

The engine to chassis and chassis to cab electrical connectors need to be inspected and possibly replaced due to possible corrosion on the products listed below. The existing connectors may fail, causing intermittent operation of the electrical system or possibly unexpected downtime. The A/C pressure switch may also need to be replaced due to a quality issue with the part. 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 12Feb2008 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 12Feb2008 Service Letter