PRODUCT SUPPORT PROGRAM FOR REPLACING THE REFRIGERANT COMPRESSOR ON DELAY TIMER ASSEMBLY (COMPRESSOR PROTECTION MODULE) ON CERTAIN 770, 772, 773F, 775F, 777D, AND 777F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE REFRIGERANT COMPRESSOR ON DELAY TIMER ASSEMBLY (COMPRESSOR PROTECTION MODULE) ON CERTAIN 770, 772, 773F, 775F, 777D, AND 777F OFF-HIGHWAY TRUCKS

Usage:

REBE6531-02

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15Oct2010

(Revised 09May2011)

U-422

A-339

D-365

O-368

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE REFRIGERANT COMPRESSOR ON DELAY TIMER ASSEMBLY (COMPRESSOR PROTECTION MODULE) ON CERTAIN 770, 772, 773F, 775F, 777D, AND 777F OFF-HIGHWAY TRUCKS
1408		PS51917

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51917" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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 15Oct2010 (Revised 18Oct2010) Service Letter. Changes have been made to the Rework Procedure.

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TERMINATION DATE

31Oct2012

PROBLEM

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The existing 169-7443 on Delay Timer assembly (Compressor protection module) for the refrigerant compressor can fail on certain 770, 772, 773F, 775F, 777D, and 777F Off-Highway Trucks. If the existing compressor module fails, it can cause the air conditioning to not function correctly.

AFFECTED PRODUCT

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Model	Identification Number
770	BZZ00069-00619
772	RLB00271-00641
773F	EED00273-01193
775F	DLS00275-01186
777D	AGC01386-02547, 75002
777F	JRP00277-02436

PARTS NEEDED

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Qty	Part Number	Description
2	3S2093	STRAP-CABLE
1	3442689	KIT-CONTROL GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Replace the existing compressor protection module with the new 338-1942 Compressor Protection Module in the 344-2689 Kit. Modify the existing harness with new gold pin contacts and connector (also in kit) to accept the new compressor protection module. Change the harness routing for the compressor protection module.

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%
0-6000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-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.

Rework Procedure

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1. Verify that the 169-7443 Control Group (Compressor Protection Module) is not operating correctly using Special Instruction REHS4499 "Testing the Refrigerant Compressor Protection Module."

2. After troubleshooting, turn the machine OFF.

3. Locate the compressor protection module. It should be located with the Air Conditioning compressor.

Image1.1.1

4. Disconnect the electrical connection, remove the retaining bolt, and remove the compressor protection module.

5. Label the wires on the harness as 1, 2, 3, and 4 according to their position in the existing plug-connector.

6. Remove the plug-connector from the existing harness and cut the existing sockets off of the wires.

7. Strip each wire back and use a 239-5260 Crimper to install a 9X-3402 Socket onto each wire.

8. The wires still have the same numbering, but their relative position on the connector has changed. Install the new sockets into the new 230-5008 Plug-Connector (3) in the following order:
Wire 1 from existing plug-connector (2) into position 1 on the new plug-connector (3).
Wire 2 from existing plug-connector (2) into position 2 on the new plug-connector (3).
Wire 3 from existing plug-connector (2) into position 3 on the new plug-connector (3).
Wire 4 from existing plug-connector (2) into position 4 on the new plug-connector (3).

NOTE: The sockets will "click" in the plug-connector when they are correctly installed. Ensure that they are correctly installed by then gently pulling on them and making sure they do not come out of the connector.

Image1.2.1

9. Install the new 338-1942 Compressor Protection Module with the existing bolt and plug in the electrical connectors.

10. Secure the wiring and connector with two cable straps.