PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENGINE AIR INLET HEATER ON CERTAIN 320D(L), 321D(L), AND 323D(L) EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENGINE AIR INLET HEATER ON CERTAIN 320D(L), 321D(L), AND 323D(L) EXCAVATORS [REBE3831]

AIR INLET AND EXHAUST SYSTEM

MANIFOLD GP-INLET

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENGINE AIR INLET HEATER ON CERTAIN 320D(L), 321D(L), AND 323D(L) EXCAVATORS

REBE3831-04

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20Aug2008

(Revised 29Jan2009)

U-432

A-352

D-357

O-395

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Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENGINE AIR INLET HEATER ON CERTAIN 320D(L), 321D(L), AND 323D(L) EXCAVATORS
1090 1920 1058		PI10706

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10706" 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 "PI10706" 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:	This Revised Service Letter replaces the 20Aug2008 (Revised 06Oct2008) Service Letter. Changes have been made to add serial numbers GKS00181-00184 to the Affected Product.

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PROBLEM

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The 168-5057 Engine Air Inlet Heater needs to be reworked on certain 320D(L), 321D(L), and 323D(L) Excavators. The air inlet heater relay can fail closed, resulting in overheating and subsequent burning of the air inlet heater, possibly causing a fire in the engine compartment with the potential for serious injury or death.

AFFECTED PRODUCT

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Model	Identification Number
320D	A6F00151-00216, 219-243, 245-262, 264-267, 271, 273-283, 285, 288, 292, 294-297, 300-301, 306 BZP00182-00345 FAL00177-00841 JFZ00199-00807 KGF00106-01257 PHX00119-00122, 124-1226, 1228-1323
320D (OEM)	GPX00300-00332
320D FM HEEL	GKS00180-00184
320D FM HW	EAX00161
320D L	A8F00153-00173, 176, 179-211, 213-292, 294-298, 300-301, 303-333, 335-363, 365, 375, 379, 382-393, 395-413, 415, 417-418, 422-423, 425, 427, 430-431, 434, 439 MGG00108-00364
320D LN	WBN00148-00192
320D LRR	TAE00106-00111 XCK00166-00201 ZGB00121-00122, 124-155
320D RR	YDS00157-00162
321D LCR	MDT00166-00180 NAS00158-00162 PBD00105-00160
323D L	BYM00107-00301, 303, 305-308, 310-317, 319-322, 325-328, 330-331, 333-334, 336-338 JLG00271-00370, 372-374 NDE00188-00213
323D LN	RAC00252-00324, 326-329, 331-334, 336-342, 344-347, 349
323D LN OEM	DCJ00103-00108, 110-111
323D SA	SED00195-00287, 289-290, 293, 296, 298-299, 301-304, 306

PARTS NEEDED

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Qty	Part Number	Description
1	5I7677	GASKET
1	5I7678	GASKET
1	3054691	HEATER-AIR
1	3208757	SOFTWARE GP-ELEK
1	3235193	SOFTWARE GP-ELEK
1	3235832	SOFTWARE GP-ELEK
1	3238204	SOFTWARE GP-ELEK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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****Parts Stock ****

Scrap all 168-5057 Engine Air Inlet Heaters from dealer parts stock.

****Affected Product****

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Refer to the attached Rework Procedure and Engine Disassembly and Assembly Manual, KENR8106.

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OWNER NOTIFIAVSION

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U.S. and Canadian owners will receive the attached Owner Notification.

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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AVSpare		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.5-hour job

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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COPY OF OWNER NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENGINE AIR INLET HEATER

MODELS INVOLVED - 320D(L), 321D(L), AND 323D(L) EXCAVATORS

Dear AVSpare Product Owner:

The 168-5057 Engine Air Inlet Heater needs to be reworked on the products listed below. The air inlet heater relay can fail closed, resulting in overheating and subsequent burning of the air inlet heater, possibly causing a fire in the engine compartment with the potential for serious injury or death. You will not be charged for the service performed.

Contact your local AVSpare dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 20Aug2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

AVSpare Inc.

Identification #(s)

Attached to 20Aug2008 Service Letter

Rework Procedure

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1. Move the machine to a flat, level surface and position the front linkage on the ground. Turn the engine key off and leave the hydraulic lock lever in the locked position. Open the engine hood cover.

2. Loosen the hose clamp that secures the air inlet hose to the air inlet elbow.

Image1.2.1

3. Remove the air inlet hose from the air inlet elbow.

4. Roll back the vinyl cap in the upper part of air inlet heater and remove the harness terminal from the air inlet heater.

Image1.4.1

5. Remove the ground harness and loosen four 303-6261 Bolts. Remove the air inlet elbow, two gaskets, and air inlet heater from the engine cylinder head.

Image1.5.1

6. Install new 305-4691 Air Inlet Heater, 5I-7677 Gasket, 5I-7678 Gasket, and previous air inlet elbow. Tighten the four 303-6261 Bolts to a torque of 17+/-2 Nm.

7. Connect the harness terminal to the air inlet heater and return the vinyl cap to the original position.

8. Fit the air inlet hose to the air inlet elbow and re-tighten the hose clamp.

9. Confirm existing ADEM Engine controller software number through E.T.

10. Decide the new ADEM Engine controller software to flash from the attached table.