PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REROUTING THE STARTER CABLE AND ALTERNATOR CABLE ON CERTAIN 966K AND 972K WHEEL LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REROUTING THE STARTER CABLE AND ALTERNATOR CABLE ON CERTAIN 966K AND 972K WHEEL LOADERS

Usage:

REBE7539-00

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07Oct2011

O-381

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REROUTING THE STARTER CABLE AND ALTERNATOR CABLE ON CERTAIN 966K AND 972K WHEEL LOADERS
1408 1403		PI31928

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31928" 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 "PI31928" 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
30Apr2012	31Oct2012

PROBLEM

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Certain 966K and 972K Wheel Loaders may have the starter cable and alternator cable in interference, at different locations, with the engine harness and other components. Those interferences could impact the resistance of the shielded cable.

AFFECTED PRODUCT

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Model	Identification Number
966K	PBG00284-00288
972K	PEM00267-00269

PARTS NEEDED

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Qty	Part Number	Description
1	1783620	STRAP-DUAL CLAMP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 37% 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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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%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-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.

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 INSPECTING AND REROUTING THE STARTER CABLE AND ALTERNATOR CABLE ON CERTAIN WHEEL LOADERS

MODELS INVOLVED - 966K and 972K Wheel Loaders

Dear Caterpillar Product Owner:

The starter cable and alternator cable needs to be inspected and rerouted on the products listed below. Certain 966K and 972K Wheel Loaders may have the starter cable and alternator cable in interference, at different places, with the engine harness and other components. Those interferences could impact the resistance of the shielded cable. 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 07Oct2011 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 07Oct2011 Service Letter

Rework Procedure

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1. Park the machine at a location where it is safe until inspection and repair can be performed. Ensure that the main disconnect switch is in the OFF position.

NOTE: This step must be taken with extreme care.

2. Place a tag that says "Do not operate" in the cab.

3. Locate the starter cable and the alternator cable interference. Refer to Image1.2.1.

Note: In this Rework Procedure, for each potential interference you will find a description of the problem and the rework associated.

Image1.2.1

Issue 1 ? Interference between the engine harness and the starter cable

Refer to Image1.3.1.

Image1.3.1

Rework Issue 1: The engine harness will need to be routed below the starter cable. It should not interfere with the engine.

Ensure that the clip harness is positioned as shown in the area circled on Image1.4.1. If it is not shown as positioned, return the engine clip harness.

Refer to Image1.4.1.

Image1.4.1

Issue 2 ? Starter cable is stretched at the flex joint

Refer to Image1.5.1.

Image1.5.1

Rework Issue 2: Reposition the starter cable on the green tape.

Refer to Image1.6.1.

Image1.6.1

Issue 3 ? Interference between the cable and the clip

Refer to Image1.7.1.

Image1.7.1

Rework Issue 3: Position the grommet so that the grommet slot is perpendicular to the clip opening.

Refer to Image1.8.1.

Image1.8.1

Issue 4 ? Interference between the starter cable and the secondary steering

Refer to Image1.9.1.

Image1.9.1

Rework Issue 4: Install a 178-3620 Dual Clamp Strap at the location of the interference.

Refer to the arrow that is shown on Image1.10.1.

A - 130-5300 (5X)
B - 8T-4121
C - 8T-4172
D - 4I-7889