PRODUCT SUPPORT PROGRAM FOR REPLACING AND INSTALLING HEATING, VENTILATION, AND AIR CONDITIONING COMPONENTS ON CERTAIN 320C, 322C, 325C, 330C FORESTRY EXCAVATORS AND 511, 521, 522, 532, 541, 551, 552, TK711, TK721, TK722, TK732, TK741, TK751, TK752, 1 Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING AND INSTALLING HEATING, VENTILATION, AND AIR CONDITIONING COMPONENTS ON CERTAIN 320C, 322C, 325C, 330C FORESTRY EXCAVATORS AND 511, 521, 522, 532, 541, 551, 552, TK711, TK721, TK722, TK732, TK741, TK751, TK752, 1090, 1190T, 129T, 1390 TRACK FELLER BUNCHERS [REBE1633]

OPERATOR STATION

AIR CONDITIONER GP

REBE1633-01

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26Mar2007

(Revised 10Sep2007)

U-112

A-94

D-95

O-103

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Before/After Parts stock action needed	PRODUCT SUPPORT PROGRAM FOR REPLACING AND INSTALLING HEATING, VENTILATION, AND AIR CONDITIONING COMPONENTS ON CERTAIN 320C, 322C, 325C, 330C FORESTRY EXCAVATORS AND 511, 521, 522, 532, 541, 551, 552, TK711, TK721, TK722, TK732, TK741, TK751, TK752, 1090, 1190T, 129T, 1390 TRACK FELLER BUNCHERS
7320		PS42367

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42367" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed form parts stock as soon as possible.

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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 AVSpare product analyst.

NOTE:	This Revised Service Letter replaces the March 26, 2007 Service Letter. Changes have been made to the Affected Product and Parts Needed.

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TERMINATION DATE

31Mar2009

PROBLEM

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The existing heating, ventilation, and air conditioning (HVAC) components can fail intermittently on certain 320C, 322C, 325C, 330C Forestry Excavators and 511, 521, 522, 532, 541, 551, 552, TK711, TK721, TK722, TK732, TK741, TK751, TK752, 1090, 1190T, 129T, 1390 Track Feller Bunchers.

The intermittent shutdown of the HVAC unit can be caused by the high amperage draw of the blower motor on the Forestry Excavators and Track Feller Bunchers.

The intermittent shutdown can also be caused by voltage spikes from the compressor clutch and the engine demand fan on the Forestry Excavators and Track Feller Bunchers.

The breakage of the blend door is a result of deformations of the HVAC unit case and is evidenced by lack of proper response to adjustments made on the cab temperature control knob.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
320C FM HW	SAH01001-01223
320C FM ST	TBR01001-01027
322C FM HW	C3R01001-01027 LAR01001-01050
322C FM LGP	BYL01001-01008
325C FM HW	M2K01001-01015 S3M01001-01019
325C FM ST	G1L01001
330C FM HW	B1K01001-01026 B4N01001-01018
330C FM ST	B3M01001

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*****Group 2*****
511	51100274-00284
521	52100304-00312, 314
522	52200238-00242
541	54100207
TK711	10100275-00276
TK721	10200367
TK722	10300465-00467

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*****Group 3*****
1190	BZK01220
1190T	BZL01320-01321, 2210
511	51100265-00273
521	52100295-00303
522	52200235-00237
532	53200175
541	54100205-00206
551	55100115-00116
552	55200145
TK711	10100245-00274
TK721	10200345-00366
TK722	10300445-00464
TK732	10400545-00549
TK741	20200225-00233
TK752	30200425

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*****Group 4*****
320C FM HW	SAH01224-01238, 1240-1242, 1244-1246, 1248-1249
322C FM HW	C3R01028
330C FM HW	B1K01027

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*****Group 5*****
320C FM HW	SAH01250-01265, 1270, 1272-1273, 1275-1279, 1282-1289, 1295, 1299-1310
320C FM ST	TBR01030-01031

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	5C2890	NUT-HEX
1	6V7646	WASHER-HARD
1	0374838	CLAMP
1	1697443	CONTROL GP-ELEK
1	1910979	WHEEL-BLOWER
1	2029041	GASKET
1	2881556	MOTOR AS
1	2951804	BRACKET AS
*****Group 2*****
1	5C2890	NUT-HEX
1	6V7646	WASHER-HARD
1	1697443	CONTROL GP-ELEK
1	2029041	GASKET
1	2951804	BRACKET AS
*****Group 3*****
1	5C2890	NUT-HEX
1	6V7646	WASHER-HARD
1	0374838	CLAMP
1	1697443	CONTROL GP-ELEK
1	1910979	WHEEL-BLOWER
1	2029041	GASKET
1	2881556	MOTOR AS
1	2951804	BRACKET AS
*****Group 4*****
1	5C2890	NUT-HEX
1	6V7646	WASHER-HARD
1	1697443	CONTROL GP-ELEK
1	2029041	GASKET
1	2951804	BRACKET AS
*****Group 5*****
1	5C2890	NUT-HEX
1	6V7646	WASHER-HARD
1	1697443	CONTROL GP-ELEK

ACTION REQUIRED

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****Parts Stock ****

Remove all 228-9045 Motors from dealer parts stock.

****Affected Product****

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Repairs will be performed as indicated below.
Group 1 Machines - Complete procedures 1, 2, and 3.
Group 2 Machines - Complete procedures 2 and 3.
Group 3 Machines - Complete procedures 1, 2, and 3.
Group 4 Machines - Complete procedures 2 and 3.
Group 5 Machines - Complete procedure 3.

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Image1

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 4.0-hour job for Group 1
An additional 1 hour will be allowed for performing Procedure 3 on machines that have had Rework Procedures 1 and 2 of PS42367 previously completed.

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 3.0-hour job for Group 2

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 4.0-hour job for Group 3

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 3.0-hour job for Group 4
An additional 1 hour will be allowed for performing Procedure 3 on machines that have had Rework Procedure 2 of PS42367 previously completed.

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-6000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-10000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 1.0-hour job for Group 5

PARTS DISPOSITION

****Parts Stock****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

****Affected Product****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Procedure 1 - Replacing the Blower Motor

Step 1) Remove the Ducts.

Step 2) Remove the 238-2923 Cover As.

Step 3) Remove the 238-2927 Tray As. (under the Cover As.)

Image1.2.1

Step 4) Remove the 251-6761 Box As.

Image1.3.1

Step 5) Disconnect the motor from the harness.

Step 6) Remove the five screws holding the Motor As. in place and remove the Motor As.

Image1.4.1

Step 7) Install the new 191-0979 Blower Wheel on the Motor and fasten it with the new 037-4838 Clamp.

Step 8) Position the 288-1556 Motor and reinstall the screws.

Step 9) Connect the Motor to the harness.

Step 10) Install the 251-6761 Box As.

Step11) Install the 238-2923 Cover As.

Step12) Install the 238-2927 Tray As.

Step13) Install the Ducts.

Procedure 2 - Replacing the Bracket

Step1) Access the HVAC unit.

Step2) Swing the 238-2923 Cover As. up to expose the HVAC unit - Secure the Cover As. to prevent it falling.

Step3) Remove the 199-7933 Control As.

Step4) Remove the 3E-5464 Switch As.

**NOTE: Do not remove the switch tube from the Evaporator.

Step5) Remove the 251-6776 Bracket.

Step6) Install the 202-9041 Gasket to the bottom side of the 295-1804 Bracket - see Image 1.6.2.

Step 7) Install the 295-1804 Bracket.

Step 8) Install the Switch As.

**NOTE: the Switch is rotated 90 degrees on the new bracket

Step 9) Install the Control As.

Image1.6.1

Image1.6.2

Procedure 3 - Installing the CPS

Step 1) Access the HVAC unit.

Step 2) Swing the 238-2923 Cover As. up to expose the HVAC unit (see Image1.6.1).

Step 3) Install the 169-7443 Control Gp to the 295-1804 Bracket with 6V-7646 Washer & 5C-2890 Nut.

Image1.7.1

Step 4) Remove 4 pin DT Connector Cap from 278-8247 Harness As.

Image1.8.1

Step 5) Connect 4 pin DT Harness Connector to 169-7443 Control Gp.

Image1.9.1

Step 6) Remove AC Clutch Relay (3E-6477) from the relay connector - this is the relay with the E554 pink wire (see Image 1.10.2).

Step 7) Cover relay connector with electrical tape.