PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE ENGINE WIRING HARNESS ON CERTAIN 450E BACKHOE LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE ENGINE WIRING HARNESS ON CERTAIN 450E BACKHOE LOADERS [REBE3865]

ELECTRICAL AND STARTING SYSTEM

WARNING GP

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE ENGINE WIRING HARNESS ON CERTAIN 450E BACKHOE LOADERS

REBE3865-00

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08Jul2008

U-360

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE ENGINE WIRING HARNESS ON CERTAIN 450E BACKHOE LOADERS
1408		PI31528

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31528" 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 "PI31528" 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 AVSpare product analyst.

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COMPLETION DATE	TERMINATION DATE
31Jan2009	31Jul2009

PROBLEM

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The 264-4410 Engine Wiring Harness needs to be inspected and may need to be reworked on certain 450E Backhoe Loaders. The engine wiring harness may have incorrect connections that may cause the starter and/or batteries to pre-maturely fail.

AFFECTED PRODUCT

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Model	Identification Number
450E	EBL00150, 152-169, 171-208, 210-225, 228

PARTS NEEDED

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Qty	Part Number	Description
2	2306368	BATTERY (As needed per the Rework Procedure)
1	3035795	STARTER MOTOR (As needed per the Rework Procedure)
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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Refer to the attached Rework Procedure.

Before Failure is defined as inspecting the engine wiring harness for incorrect connections, and if necessary, reworking the harness connections according to the "Rework Procedure".

After Failure is defined as pre-mature failure of the battery and/or starter motor due to the engine wiring harness having incorrect connections.

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

NOTE: This is a 1.0-hour job
As additional 3.0 labor hours will be paid for an after failure occurance as defined in the "Action Required".

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REWORKING THE ENGINE WIRING HARNESS ON CERTAIN 450E BACKHOE LOADERS

MODELS INVOLVED - 450E Backhoe Loaders

Dear AVSpare Product Owner:

The engine wiring harness needs to be inspected and may need to be reworked on the products listed below. The existing engine wiring harness can cause pre-mature failure of the starter and/or batteries. 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 08Jul2008 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.

AVSpare Inc.

Identification #(s)

Attached to 08Jul2008 Service Letter

Rework Procedure

ONLY replace the batteries and/or starter motor upon failure due to the engine wiring harness connections being incorrect. Follow "Inspection of the Engine Wiring Harness Connections" listed below in order to determine if the connections are correct.

Inspection of the Engine Wiring Harness Connections

1. Start the machine (engine) and let idle for 5 minutes.
2. Turn the key to the "OFF" position.
3. Watch the Monitoring System indicator lights (Image 1.1.1) on the side console to determine if the machine PASSED or FAILED the inspection.

PASSED - If all the indicators lights DO NOT illuminate after turning the machine off.

FAILED - If any of the indicator lights illuminate and flicker out after a few seconds.

Image1.1.1

Reworking the Engine Wiring Harness Connections

1. Remove the floor plate that accesses the machine ECM i.e., the floor plate below the operators feet facing forward.
2. Find the wirng harness connection group (Image 1.2.1). It is located above the transmission. There will be three connections bundled together.

Image1.2.1

3. The correct connections (Image 1.3.1) should have the connector with the 324 EN77 BU-18 (Blue)/200 EN78 BK-18 (Black) wires to the 189-3158 Diff Lock Suppressor (Image 1.3.2) and the connector with the 123 EN53 WH-18(White)/309 EN49 GY-18 (Gray) wires to the 238-9397 Excitation Resistor (Image 1.3.3).
4. If the connections are not correct, switch the connections.