PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW STARTER MOTOR AND REWORKING THE ELECTRICAL ROUTING SYSTEM ON CERTAIN 216B3 AND 226B3 SKID STEER LOADERS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW STARTER MOTOR AND REWORKING THE ELECTRICAL ROUTING SYSTEM ON CERTAIN 216B3 AND 226B3 SKID STEER LOADERS

Usage:

TEBE6762-00

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26Mar2018

U-169

A-126

D-149

O-155

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW STARTER MOTOR AND REWORKING THE ELECTRICAL ROUTING SYSTEM ON CERTAIN 216B3 AND 226B3 SKID STEER LOADERS
1453		PS53718

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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 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 "PS53718" 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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TERMINATION DATE

31Mar2021

PROBLEM

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The existing starter motor can allow water ingress, resulting in internal rust that causes motor to stop functioning, on certain 216B3 and 226B3 Skid Steer Loaders.

AFFECTED PRODUCT

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Model	Identification Number
216B 3	HR200115-00345 PWK00100-00102, 105-112, 114-2190
226B 3	DXZ00110-00112, 115-1568, 1570-1572

PARTS NEEDED

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Qty	Part Number	Description
1	1A8912	WASHER
4	3S2093	STRAP-CABLE
1	5C2890	NUT-HEX
1	5C7261	NUT-HEX
2	6I0593	BOLT-FLANGE HEAD
8	7K1181	STRAP-CABLE
1	8F7242	WASHER
1	4605100	MOTOR-STARTING
1	5395879	HARNESS AS
1	5395880	CABLE AS-POS
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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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%
0-1500 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-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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Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

Refer to the Service Manual if/as necessary. Turn off the engine and ensure engine compartment reaches ambient condition before starting the below rework.

1. Remove the battery terminals using a spanner and mask both battery terminals. Ensure that proper masking is done in order to prevent the terminals from touching other parts. Remove the negative cable from the machine (this is to install new starter motor). Refer to Image1.2.1.

Image1.2.1

2. Remove the air intake hose connected to the air cleaner as shown in Image1.3.1 by disassembling the clamp. To avoid contamination, cover the intake hose with masking tape.

Image1.3.1

3. Remove the air filter and harness connected to the air filter. Refer to Image1.4.1.

Image1.4.1

4. Remove the engine harness from the machine.

5. Remove the 172-9200 Four Pin Diode. Refer to Image1.6.1. Retain the diode for later reuse in the new harness. Refer to Image1.6.1.

Image1.6.1

6. Remove the existing starter motor from the engine and install a new 460-5100 Starter Motor. Install the 6I-0593 Bolts and connect negative cable terminal to the lower bolt. Refer to the area circled in Image1.7.1. Tighten the bolts to a specified torque of 50 N.m. Refer to Image1.7.1.

Image1.7.1

7. Install the removed 172-9200 Four Pin Diode that was retained to the connector in the new 539-5879 Engine Harness Assembly, as shown in Image1.8.1, and tie back to main bundle with a new 3S-2093 Cable Strap.

Note: Ensure that the diode is inserted properly and fully seated in the harness connector.

Image1.8.1

8. Place the new 539-5879 Engine Harness Assembly on the engine. Refer to Image1.9.1.

Image1.9.1

9. Tie the 2-pin diode and 2-pin resistor connectors back to the main bundle and secure the harness assembly with three 7K-1181 Cable Straps. Refer to Image1.10.1.

Image1.10.1

10. Route the harness assembly along the clip ladder and secure using a new 7K-1181 Cable Strap. Refer to Image1.11.1.

Image1.11.1

11. Secure the harness assembly to the coolant temperature sensor using a new 3S-2093 Cable Strap. Refer to Image1.12.1.

Image1.12.1

12. Reuse the 1A-8912 Washer, 1H-3244 Lock Washer, and 5C-2890 Nut (M6). Secure the wire to the alternator power stud in order of lock washer, terminal, washer, and nut. Refer to Image1.13.1. Tighten the 5C-2890 Nut to a specified torque of 5 +/- 0.5 N.m. Secure the connection with a wire boot. Refer to Image1.13.1.

Image1.13.1

13. Reuse two 4B-4272 Washers, two 6C-9081 Lock Washers, and two 5C-2874 Nuts (M5). Secure the wire to the remaining alternator studs. Secure the 403-Green Wire in the bottom stud and the C444-Yellow Wire in the middle stud. Refer to Image1.14.1. Tighten the 5C-2874 Nut to a specified torque of 2.25 +/- 0.25 N.m.

Image1.14.1

14. Route the starter solenoid terminal wire along the harness and connect it to the starter motor stud. Refer to Image 1.15.1. Install the 1A-8912 Washer and 5C-2890 Nut. Tighten the nut to a specified torque of 5 +/- 0.5 N.m. Tie the wire back to the main bundle using a 3S-2093 Cable Strap.

Image1.15.1

15. Route the 539-5880 Cable Assembly. Refer to Image1.16.1. First connect the 45 degree terminal to the starter motor battery terminal and then install the battery positive cable. Install the 8F-7242 Washer and 5C-7261 Nut. Tight the nut to 12 to 15 N.m. Cover the terminal with the boot provided with the positive cable.

Image1.16.1

16. Route the harness assembly. Refer to Image1.17.1. Secure the glow plug harness with a 3S-2093 Cable Strap and tighten to a specified torque to 1.7 +/- 0.25 N.m. Route and connect to the oil pressure switch and secure to the clip ladder with a 7K-1181 Cable Strap.

Image1.17.1

17. Route and secure the harness assembly to the fuel shut down switch. Refer to Image1.18.1.

Image1.18.1

18. Install a 7K-1181 Cable Strap to secure the fuel shutoff solenoid connector on the ladder clip. Refer to Image1.19.1.

Image1.19.1

19. Secure two ends from the harness assembly to the studs on the fuse and reassemble it in the order of lock washer, harness terminal washer, and nut. Tighten the nut to a specified torque of 14 +/- 1 N.m. Replace the fuse cover. Refer to Image1.20.1.

Image1.20.1

20. Plug the connector with yellow and black wires into the front relay. Refer to Image1.21.1.

Image1.21.1

21. Install two 7K-1181 Cable Straps to secure the harness assembly to the weld links. Refer to Image1.22.1.

Image1.22.1

CAUTION - Ensure that wire is NOT in contact with metal parts. Refer to Image1.23.1.

Image1.23.1

22. Locate and connect the 12 pin platform harness switch to the engine harness switch at the rear left hand side of the lower frame. Refer to Image1.24.1.

Image1.24.1

23. Install the air filter to the chassis and tighten to a specified torque of 15 +/- 3 N.m. Assemble the air filter hose to the air filter and tighten the clamp to a specified torque of 7 +/- 1 N.m. and then connect the air filter connector to the air filter. Refer to Image1.25.1.

Image1.25.1

24. Remove the masking tape from the battery terminal. Secure the negative and positive terminals to the correct battery ports.

25. Route the negative cable under the positive and then tighten the cable using a 7K-1181 Cable Strap to the clip ladder provided. Refer to Image1.26.1.

Image1.26.1

26. Ensure that the terminals are seated all the way down on the battery post and tighten the battery bolts to a specified torque of 7.2 +/- 1.6 N.m.

The installation is complete. Check all harness connection and ensure that bare wires not touching metal surfaces and then tighten.