PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FRONT AND REAR HARNESSES ON CERTAIN CD54 ASPHALT COMPACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FRONT AND REAR HARNESSES ON CERTAIN CD54 ASPHALT COMPACTORS

Usage:

REBE9340-00

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31Jan2013

U-36

O-36

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FRONT AND REAR HARNESSES ON CERTAIN CD54 ASPHALT COMPACTORS
1408		PI32138

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32138" 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 "PI32138" 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
31Jul2013	31Jan2014

PROBLEM

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The front and rear harnesses need to be reworked on certain CD54 Asphalt Compactors. The routing of the existing harnesses along the hydraulic hoses can cause the wires to vibrate, fatigue, and result in a failure.

AFFECTED PRODUCT

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Model	Identification Number
CD54	J5R00101, 104-176, 178-197, 200-214

PARTS NEEDED

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Qty	Part Number	Description
8	3S2093	STRAP-CABLE
2	4P7581	CLIP-LADDER
4	5C7261	NUT-HEX
16	7K1181	STRAP-CABLE
8	7T1099	LINK
4	7X2537	BOLT-HEX HEAD
8	8T4224	WASHER-HARD
6	8T8737	PLUG-SEAL
19	9X3402	SOCKET-CONNECTOR
4	1325789	CLIP-LADDER
4	1552274	PLUG KIT-CONN
2	4309969	HARNESS AS
2	4309972	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 41% 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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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%

NOTE: This is a 6.0-hour job

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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FRONT AND REAR HARNESSES ON CERTAIN CD54 ASPHALT COMPACTORS

MODELS INVOLVED - CD54 ASPHALT COMPACTORS

Dear Cat Product Owner:

The front and rear harnesses need to be reworked on the products listed below. The existing harness can cause wires to fail intermittently. 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 31Jan2013 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 31Jan2013 Service Letter

Rework Procedure

Ensure that PI32086 has been performed prior to administering this service letter.

If PI32086 has not been completed, make sure it is completed first or follow the Instructions for Software Installation, Steps 1-5 and then complete the Harness Installation.

If PI32086 has been completed the software installation is not required. Skip to the Harness Installation section in the rework procedure, Steps 1-12.

Instructions for Software Installation

1. Obtain the new software. The software is available on Service Information System in the Downloads. Under the Paving Products heading download "CD54_Diagnostics.zip", the heading for this is "CD54 Flash and Diagnostic File."

2. Connect the Plus 1 Guide Service Tool software to the machine.

3. In the Plus 1 Service Tool select File Download. Select the controller labeled with the part number 3401914 or 10107147. Refer to Troubleshooting, KENR7099, "Electronic Control Module (ECM)-Flash Program".

4. Now select software part number 4228961REV00.lhx to flash into the controller. Refer to Troubleshooting, KENR7099, "Electronic Control Module (ECM)-Flash Program".

5. Check that machine has no fault codes, it is possible that calibrations will need to be performed. If so refer to the calibration procedures in, Testing and Adjusting, KENR5738, "CD54 Vibratory Asphalt Compactor Propel System," and Testing and Adjusting, KENR5740, "CD54 Vibratory Asphalt Compactor Machine Systems."

Harness Installation

The following are installation instructions for the 430-9969 and 430-9972 Jumper Harnesses. In order to install the 430-9969 and 430-9972 Harnesses the existing center harnesses (313-9067 and 346-7536) will need to be reworked. (or replaced with new 430-9971 and 430-9974 Harnesses - not included in this program) These instructions will show you how to rework your existing center harnesses (313-9067 and 346-7536) with out having to remove them from the machine.

Image1.2.1

1. Remove side cover plate from all 4 corners to expose the hoses and harnesses.

Image1.3.1

2. Remove stauff clamp stack closest to the harness that goes to the speed sensors. Pull the hydraulic hoses to the side. Secure hydraulic hoses using cable straps.

Image1.4.1

Image1.4.2

Image1.4.3

3. Prep folded support surface for welding. Weld one weld link to the inside of each folded support. The images below are from the Front Right side of the machine.

a. Shown is the weld link and jumper harness on the front right side of the machine, Image 1.5.1. Image 1.5.2 is a view of the folded support if you were sitting in the middle of the drum. Dimension X is 120mm.

b. Shown in Image 1.5.3 is the weld link from the side, place the weld link in the center of this flat area approximately 100mm (Y) from the vertical surface of the folded support.

NOTE: These same dimensions can be used for the weld links on all 4 folded supports. The location will be similar on the side of folded support with the large hole for towing.

Image1.5.1

4. Prep the surface of the hose retention plate for welding. Place weld link approximately 30mm from the edge of the folded support and centered on the plate vertically.

Image1.6.1

5. Cut center harness between the weld link added on the hose retention plate and the weld link on the bumper just above the plate, both are shown in image 1.7.1. Remove lower portion of harness from machine.

Image1.7.1

6. Crimp 9X-3402 Sockets on all wires that were clipped. Add 155-2274 DT Connectors to remaining portion of center harness. The table in 1.8.1 is for the Front Left/Rear Right corner that contains the propel speed sensor. Use the 430-9972 Harnesses on the Front Left and Rear Right corners of the machine.

Image1.8.1

7. The table in image 1.9.1 is for the Front Right/Rear Left corner that contains the propel speed sensor and the vibe speed sensor. Use the 430-9969 Harness on the Front Right and Rear Left corners of the machine.

Image1.9.1

8. Attach harness to weld link that was added on the hose retention plate. Use 2 - 3S-2093 Cable Straps to attach the harness as shown in Image 1.10.1.

Image1.10.1

9. Route harness along folded support and attach harness to the weld link added on the folded support as shown in 1.11.1. Ensure that the heat shrink on out side of the harness lands inside the weld links and the 7K-1181 Cable Strap is secured around the heat shrink.

Image1.11.1

10. Route harness from the folded support to the drive plate. When routing on the Front Left/Rear Right corners add 1 ladder clip (132-5789) to the drive plate using the 7X-2537 Bolt, 5C-7261 Nut, and 8T-4224 Washer. Route the portion of the harness going to the propel speed sensor as shown in Image 1.11.1. Use a 7K-1181 Cable Strap to secure harness. Use existing ladder clip and a 7K-1181 Cable Strap to secure connector for the propel speed sensor.

Image1.12.1

Image1.12.2

11. When routing on the Front Right/Rear Left corners first move the Deutsch clip for the vibe speed sensor one hole over on the drive plate. Then, add 1 each of 4P-7581 and 132-5789 Ladder Clips using the 7X-2537 Bolt, 5C-7261 Nut, and 8T-4224 Washer as shown in 1.13.1 and 1.13.2. Route harness to vibe speed sensor and propel speed sensor using 7K-1181 Cable Strap to secure the harness to the ladder clips. Secure the propel speed sensor connector to the 4P-7581 Ladder Clip and the vibe speed sensor harness to the 132-5789 Ladder Clip.

12. With the new jumper harnesses installed, re-assemble the hoses back into the stauf clamps. Install cover plate over hoses and test machine functionality. Specifically perform the "Vibratory Frequency - Test and Adjust - Two Amplitude System" from KENR5740 and "Speed Sensor (Propel Motor) - Test" from KENR5738.