PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING AND REROUTING THE ENGINE HARNESS ON CERTAIN 902C2 AND 903C2 COMPACT WHEEL LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING AND REROUTING THE ENGINE HARNESS ON CERTAIN 902C2 AND 903C2 COMPACT WHEEL LOADERS

Usage:

TEBE3943-00

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01Dec2015

D-559

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING AND REROUTING THE ENGINE HARNESS ON CERTAIN 902C2 AND 903C2 COMPACT WHEEL LOADERS
1408 1403		PI32580

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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 as soon as possible. When reporting the repair, use "PI32580" 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 "PI32580" 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
30Jun2016	31Dec2016

PROBLEM

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The engine harness needs to be repaired and rerouted on certain 902C2 and 903C2 Compact Wheel Loaders. The existing wiring can be damaged.

AFFECTED PRODUCT

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Model	Identification Number
902C 2	YKT00154, 157, 159, 166, 176, 179-182, 186-187, 205, 216
903C 2	YKL00153, 156, 163-165

PARTS NEEDED

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Qty	Part Number	Description
1	3S2093	STRAP-CABLE
2	7K1181	STRAP-CABLE
3	9X3402	SOCKET-CONNECTOR
1	1552260	PLUG KIT-CONN
1	4958617	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Rework the engine harness, add a jumper harness, and change the binding of wiring.
Before completing the attached Rework Procedure, please review the safety actions in the Operation and Maintenance Manual for your machine.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

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 3.0-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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING AND REROUTING THE ENGINE HARNESS

MODELS INVOLVED - CERTAIN 902C2 AND 903C2 COMPACT WHEEL LOADERS

Dear Cat Product Owner:

The DPF differential pressure sensor harness needs to be repaired on the products listed below. The existing harness can be damaged. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 01Dec2015 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 01Dec2015 Service Letter

Rework Procedure

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1. Park the machine in a safe, hard flat area, lower all the attachments to the ground, shut off the engine and, wear all the required Personal Protection Equipment.

2. Disconnect the battery before starting this Rework Procedure.

3. Remove four bolts (A) located under cover (B). Refer to Image1.2.1.

Image1.2.1

4. Cut the wiring connected to the differential sensor at location (C). Refer to Image1.3.1.

5. Return cut wiring (D) to binding region.

Image1.3.1

6. Add additional connector (E) on cut wiring with three 9X-3402 Sockets, 155-2276 Wedge in 155-2260 Connector Plug Kit and 155-2267 Plug Assembly. Refer to Image1.4.1.

7. Add new 495-8617 Jumper Harness Assembly (F) and fix at extra binding.

Image1.4.1

8. Add 479-4341 Bracket (binding plate) (G). The two washers between the sensor and the mounting bracket at location (H) will not be reused. Tighten to a specified torque of 6 +/- 1 N.m. Refer to Image1.5.1.

Note: The 479-4341 Bracket (binding plate) has been provided individually.

9. Bind the wiring with 3S-2093 Cable Strap (J).