PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE POSITIVE REMOTE START JUMP LUG AND COMPONENTS ON CERTAIN 416F, 420F, AND 430F BACKHOE LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE POSITIVE REMOTE START JUMP LUG AND COMPONENTS ON CERTAIN 416F, 420F, AND 430F BACKHOE LOADERS

Usage:

TEBE4663-01

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01Jun2016

(Revised 08Jun2016)

U-284

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE POSITIVE REMOTE START JUMP LUG AND COMPONENTS ON CERTAIN 416F, 420F, AND 430F BACKHOE LOADERS
1408 7620		PI32634

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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 "PI32634" 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 "PI32634" 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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NOTE:	This Revised Service Letter replaces the 01Jun2016 Service Letter. Changes have been made to the Parts Needed to include the correct spacer part number and add the cover to the required parts list.

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COMPLETION DATE	TERMINATION DATE
31Dec2016	30Jun2017

PROBLEM

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The positive remote jump start lug and mating components need to be replaced on certain 416F, 420F, and 430F Backhoe Loaders. The existing positive jump start lug can rust or corrode grounding the positive side of the circuit to the chassis.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
416F	LWT00322, 328, 330, 345, 498-501, 668-669, 699, 701, 705, 730, 773, 775
420F	LKH00158-00159, 164-173, 175-176, 178-179, 181, 183-189, 191-217, 228-234, 238-280, 287-311, 315-339, 344-345, 347-369, 371-372, 374-380, 382-384, 386-396, 398-399, 401-404, 406-408, 411-413, 415-424, 426-481, 483-485, 491-509, 512-514, 516 LTG00546, 549, 569-570, 613, 620-621, 627-628, 631, 693, 700, 1107, 1112, 1119, 1266-1275, 1384-1388, 1509, 1518, 1521, 1531, 1533, 1548-1550, 1579, 1785, 1787-1788, 1797, 1971-1972, 2137-2141, 2143, 2322-2323, 2332-2333, 2335-2342
420F IT	JWJ00190, 192, 196-197, 209, 219, 225, 296, 363, 367-370, 372-373, 378-379, 381, 385-389, 391-397, 399-400, 415, 422, 475-480, 485-486, 497-498, 506-508, 518, 568-569, 575, 578-580, 587, 596-599, 642-655, 659-663, 666, 669, 771-774, 792-798, 800-803, 881, 883, 885, 887, 890, 892-899, 901, 903-905, 907, 914-916, 918-921, 924, 1006, 1044, 1547, 1586, 1643, 1723-1724, 1907, 1909, 2827, 2947-2948, 2958, 2960, 2962-2967, 2970-2971, 2973
420F ST	SKR00200, 212, 215, 270, 868, 1192, 1194, 1206, 1286, 1308, 1318, 3205
430F	LDY00171-00172, 181, 186, 191, 202, 206-208, 218-220, 235-236, 250, 254-255, 266-269, 275-278 LNH00150, 153-155, 165-170, 173-174, 180, 182, 184-185, 187-188, 195-200, 208
430F IT	RGS00151, 233, 251, 281, 292, 354-356, 570
430F ST	RDF00193, 247, 308, 315, 402

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*****Group 2*****
420F	LKH00381 LTG02165
420F IT	JWJ00160, 179, 186, 198, 601, 768-769, 882, 1246, 1248, 1425-1426, 1604, 1679-1680, 1906, 2040, 2353-2354, 2432, 2545-2547, 2940, 3038, 3068-3070, 3274, 3278
420F ST	SKR00169, 213, 216, 302, 305, 311, 316, 319, 719, 958, 2267-2268, 3553, 3712, 4597-4598, 4927, 5008, 5246, 5249
430F	LDY00190, 225
430F IT	RGS00381, 394, 481, 573, 688
430F ST	RDF00158, 313, 526-527, 603, 754

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3S2093	STRAP-CABLE
1	1060800	CONNECTOR GP-BSC
1	1246524	SPACER
1	1511340	GREASE
1	3832789	COVER
1	3838936	STUD
1	3838937	RECEPTACLE
1	3885359	RETAINER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 19% 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.
*****Group 2*****
1	3S2093	STRAP-CABLE
1	1060800	CONNECTOR GP-BSC
1	1246524	SPACER
1	1511340	GREASE
1	3832789	COVER
1	3838936	STUD
1	3838937	RECEPTACLE
1	3885359	RETAINER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 19% 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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 1

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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

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 REPLACING THE POSITIVE REMOTE START JUMP LUG AND COMPONENTS

MODELS INVOLVED - CERTAIN 416F, 420F, AND 430F BACKHOE LOADERS

Dear Cat Product Owner:

The positive remote jump start battery lug and surrounding components needs to be replaced on the products listed below. The existing jump start lug can corrode and create a ground path for the positive side of the circuit. 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 01Jun2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 01Jun2016 Service Letter

Rework Procedure

Note: Refer to the machines Operation and Maintenance Manual for the proper Safety procedures.

1. Park the machine on a flat stable area.

2. Turn off the engine and engage the parking brake.

3. Turn the machines battery disconnect switch to the OFF position.

4. Locate the positive remote battery jump start lug and cable on the machine. Refer to Images1.1.1, 1.1.2, and 1.1.3.

Image1.1.1

Image1.1.2

Image1.1.3

5. Remove the 347-5947 Fender to obtain access to the jump start lug assembly. Refer to Image1.2.1.

Image1.2.1

6. Remove the cable strap (take care not to damage the cable) and slide the red rubber 276-1786 Boot up the cable to expose the cable connection. Refer to Images1.3.1 and 1.3.2.

Image1.3.1

Image1.3.2

7. Remove the 9B-9146 Nut and 331-5518 Cable from the post.

8. Remove the 062-5388 Locknut and disconnect the 383-2789 Cover and 106-0800 Post from the 419-8656 Mounting Bracket. The 9B-9146 Nut, 062-5388 Locknut, and 383-2789 Cover will not be reused. Refer to Image1.4.1.

9. Remove the RED 277-5777 Post Cover from the new 106-0800 Connector. The RED 277-5777 Post Cover will not be reused. Refer to Image1.4.2.

Image1.4.1

Image1.4.2

10. Assemble the 383-8936 Stud, 383-8937 Receptacle, and 383-5359 Retainer to the 383-2789 Cover.

11. Assemble the new 383-2789 Cover and 106-0800 Post to the 419-8656 Mounting Bracket. Tighten the 062-5388 Locknut to a specified torque of 10.8 - 13.5 N.m.

12. Attach the 124-6524 Spacer, then the 331-5518 Cable to the 106-0800 Post using the 9B-9146 Nut. Tighten the nut to a specified torque of 8.1 - 10.8 N.m.

13. Apply generous amounts of 151-1340 Dielectric Grease to all metal components.

Note: A suitable electrical grade silicone RTV compound may be substituted. Refer to Image1.5.1.

14. Return the 276-1786 Boot to the location shown in Image1.5.2 and install the 3S-2093 Cable Strap. Refer to Image1.5.2.

15. Reinstall the 347-5947 Fender.