PRODUCT IMPROVEMENT PROGRAM FOR ISOLATING THE 209-5582 AIR INLET HEATER RELAY ON CERTAIN C9 EQUIPPED PRINOTH SNOW GROOMERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR ISOLATING THE 209-5582 AIR INLET HEATER RELAY ON CERTAIN C9 EQUIPPED PRINOTH SNOW GROOMERS

Usage:

REBE5412-01

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06Jan2010

(Revised 21Jan2010)

U-8

D-6

O-8

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR ISOLATING THE 209-5582 AIR INLET HEATER RELAY ON CERTAIN C9 EQUIPPED PRINOTH SNOW GROOMERS
1090 7499 1408		PI31712

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31712" 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 "PI31712" 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 06Jan2010 Service Letter. Changes have been made to Parts Needed.

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COMPLETION DATE	TERMINATION DATE
31Jul2010	31Jan2011

PROBLEM

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The 209-5582 Air Inlet Heater Relay on certain C9 equipped Prinoth snow groomers may fail resulting in dead batteries, the relay stuck ON, or the relay not energized. The air inlet heater relay needs to be isolated from the engine.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C9	CLJ00514, 4522, 4574, 4584, 5802, 6350, 6360-6364, 6366-6370, 6423-6432, 6458, 6460-6468, 6753-6760, 6763-6764, 6832-6834, 6836-6837, 6839, 6843-6845, 6847, 6903-6907, 6909-6914, 6917, 6919, 6921-6922, 6976-6977, 6979, 6982, 6984, 6987, 6990, 6993, 6995, 6997, 7052-7055, 7057-7067, 7077-7078, 7080-7081, 7083, 7085, 7087-7090, 7166-7171, 7223-7224, 7226-7228, 7232-7234, 7264, 7268, 7271-7274, 7278, 7331-7332, 7334-7336, 7338-7339, 7341-7342, 7613, 7730, 8942-8944, 8964, 8966, 8974-8976, 9010, 9014, 9060, 9064, 9069, 9073, 9075, 9078, 9080, 9119, 9124-9125, 9129, 9134, 9136, 9139, 9141, 9146-9147, 9150, 9152-9154, 9156, 9158, 9160, 9167, 9169-9170, 9196, 9207-9211, 9213, 9215, 9218, 9223-9224, 9226, 9240, 9243, 9247-9250, 9306-9313, 9315-9316, 9368, 9371, 9373, 9375-9376, 9380-9384, 9515-9521, 9523, 9528, 9530, 9567, 9617-9623, 9625-9627, 9645, 9647, 9656-9665, 9721-9723, 9744-9745, 9747, 9904, 10156-10157, 10159-10168, 10175-10180, 10280-10289, 10314-10321, 10385-10390, 10608-10611, 10615-10618, 10620, 10622, 10641, 10643, 10646, 10650, 10655, 10658, 10664, 10666, 10669, 10672, 10677, 10679, 10681, 10683, 10686, 10688, 10691-10694, 10706, 10708-10712, 10714-10716, 10718, 10720, 10725-10726, 10730, 10733, 10756, 10758-10759, 10766, 10777, 10940, 10943, 10947-10951, 10953-10955, 10965-10973, 10988, 10991, 10995

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*******Group 2*******

JSC00101, 513-514, 819, 822-824, 1051-1054, 1056, 1061, 1063, 1065, 1067, 1069, 1212-1221, 1302, 1304-1309, 1311-1313, 1413, 1417-1418, 1421, 1423-1424, 1426-1428, 1430-1431, 1471-1480, 1515-1518, 1520, 1522-1525, 1527-1532, 1535-1536, 1598, 1614-1621, 1627-1630, 1672-1676, 1698, 1700, 1702-1703, 2241, 2252, 2338, 2344-2346, 2354, 2360-2361, 2363, 2366, 2370, 2488, 2490-2498, 2513-2514, 2519-2521, 2524, 2526, 2530, 2532, 2536-2537, 2541, 2544, 2547-2548, 2550, 2552, 2554-2555, 2557-2558, 2570, 2605, 2612, 2617-2619, 2621, 2624-2626, 2628, 2666-2668, 2671, 2674, 2676-2678, 2682, 2684-2686, 2688, 2697, 2700-2701, 2704-2705, 2711, 2718, 2821, 2840, 2842, 2844-2850, 2855, 3036-3037, 3040, 3049, 3056, 3058, 3066, 3069, 3073, 3078-3079, 3098, 3102, 3105, 3107, 3110-3111, 3116, 3118, 3129, 3131, 3134-3135, 3137-3141, 3143-3145, 3219, 3221-3222, 3224, 3227-3231, 3238, 3337, 3341, 3343, 3350-3354, 3356-3358, 3360-3361, 3363-3364, 3367-3369, 3886, 3888-3889, 3893-3894, 3896-3903, 3906, 3908, 3918, 3941, 3945, 3952, 3954-3955, 3957-3958, 3960, 3962-3963, 3967, 3985, 3990-3991, 4596-4597, 4711, 4713, 4931, 4938, 5099, 5101, 5364-5366, 5369-5374, 5914, 5916, 5920, 5926, 5928, 5933, 5935, 5938-5939, 5949, 6013-6014, 6016, 6021, 6023, 6033, 6035, 6039-6041, 6044, 6050, 6053, 6057, 6059, 6061, 6067, 6071, 6073, 6078-6079, 6082-6085, 6087-6088, 6090-6093, 6095-6102, 6104, 6106-6109, 6112-6120, 6122-6123, 6130, 6132, 6137, 6144-6145, 6148, 6150, 6154, 6158-6159, 6161-6162, 6165, 6167, 6170, 6173, 6175, 6179, 6181-6182, 6184-6185, 6407, 6409, 6411-6412, 6414-6416, 6420, 6436, 6441, 6454, 7022, 7025, 7029, 7031, 7038, 7042-7043, 7052, 7073, 7085, 7089, 7101, 7115, 7118, 7123, 7249, 7260, 7273, 7289, 7293-7294, 7306, 7310, 7317, 7321, 7561, 7567, 7573, 7581, 7598, 7600, 7605-7606, 7608, 7612, 7620, 7624, 7627, 7630, 7885, 7888, 7892-7893, 7898, 7911-7914, 7917, 7928-7929, 7937-7938, 7942, 7944-7946, 7953-7954, 7957, 7959, 7962, 7966-7967, 7971, 7978-7979, 7984, 7987, 8010, 8016, 8018, 8022, 8025-8026, 8028-8029, 8036-8037, 8044-8045, 8150, 8152, 8154, 8156-8159, 8161, 8164-8166

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
7	3B4504	LOCKWASHER-1/4
1	3495805	KIT- PRINOTH (As Required)
1	3495806	KIT-PRINOTH (As Required)
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.
*****Group 2*****
7	3B4504	LOCKWASHER-1/4
1	3495806	KIT-PRINOTH
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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Give careful attention to the groups and the serial numbers to determine the appropriate kit part number and procedures for each unit. Refer to the attached Rework Procedure for complete details for reworking each group.

GROUP 1 - Tier II Prinoth snow groomers.

NOTE: Some Group 1 Tier II snow groomers were built with a vertical electrical panel. Use 349-5806 Kit for machines with vertical mounted electrical panels.

GROUP 2 - Tier III Prinoth snow groomers.

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OWNER NOTIFICATION

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

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 2.0-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 2.0-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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR ISOLATING THE 209-5582 AIR INLET HEATER RELAY

MODELS INVOLVED - C9 equipped Prinoth snow groomers

Dear Caterpillar Product Owner:

The 209-5582 Air Inlet Heater Relay may fail on the products listed below. The failure may result in dead batteries, the relay stuck ON, or the relay not energized. The air inlet heater relay needs to be isolated from the engine. You will not be charged for the service performed.

Contact your local Caterpillar 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 06Jan2010 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.

Caterpillar Inc.

Identification #(s)

Attached to 06Jan2010 Service Letter

Rework Procedure

Group Number 1

1. Remove all power to the engine following local lock out tag out procedures. Remove power to the electrical panel by removing the negative cable from the battery. Remove the air inlet heater relay assembly and all associated wiring from the current mounting point on the engine. These parts will not be reused. Refer to Image1.1.1

Image1.1.1

2. A new 209-5582 Air Inlet Heater Relay will be mounted to the right, outside wall of the circuit breaker panel. Remove the access cover from the electrical panel. Remove the four mounting bolts holding the electrical panel to the deck. Refer to Image1.2.1

Image1.2.1

3. Carefully tilt the electrical panel so that the right side is facing upwards. Use existing the lower hole on the panel to mount the 209-5582 Air Inlet Heater relay to the right side of the panel. The 209-5582 Air Inlet Heater Relay must be mounted level on the right side of the panel. Use the new 209-5582 Air Inlet Heater Relay as a template to mark spacing of holes to be drilled for isolation mounts. Drill two 15mm or 9/16" holes on the right side of electrical panel.

NOTE: When drilling holes in the panel take care not to damage the existing wiring or cables. To avoid the possibility of electrical shorts in the electrical panel, remove any metal chips created during the drilling process. Refer to Image1.3.1

Image1.3.1

4. Remove the rubber isolation mounts from 283-1226 Bracket. Remove the metal inserts from the isolation mounts. Insert the rubber portion of the isolation mount into the 15mm or 9/16" diameter holes in the panel until it locks in place at the center groove. Refer to Image 1.4.1. Reinstall the metal inserts through the rubber isolation mounts from the inside of the electrical panel. Refer to Image 1.4.2

Image1.4.1

Image1.4.2

NOTE: The 209-5582 Air Inlet Heater Relay must be mounted outside of the electrical panel for this installation.

Refer to Image1.6.2 for relay nut and bolt location references and torque requirements.

5. Attach the new 209-5582 Air Inlet Heater Relay to the isolation mounts using two 208-9277 Bolts (5). Tighten the 208-9277 Bolts to a torque of 12 +/- 1 Nm (9 +/- 1 lb ft). Remove the existing air inlet heater power cable from the electrical panel. This cable will not be reused.

6. Connect the new 349-4777 Cable to the rear wire terminal of the 209-5582 Air Inlet Heater Relay power stud. Refer to image 1.5.1. Tighten the nuts (2) to a torque of 9 +/- 1 Nm (7 +/- 1 lb ft). Hold nut (6) with an additional wrench while tightening nut (2) to prevent nut (6) from turning.

7. Connect the other end of the 349-4777 Cable to the air inlet heater circuit breaker power connection. Secure the 349-4777 Cable to the existing wiring with 3S-2093 Cable Straps as needed.

Image1.5.1

8. Remove the existing cable from the air inlet heater element. This cable will not be reused.

9. Securely connect the new 340-6323 Cable and the existing Prinoth heater indicator lamp wire to the air inlet heater element. Be sure good electrical connection is made by both the cable and the indicator wire. Tighten the nut to a torque of 9 +/- 1 Nm (7 +/- 1 lb ft).

10. Connect the 339-8835 Harness to the air inlet heater relay control engine harness connector. Route the 340-6323 Cable and 339-8835 Harness to the electrical panel.

11. Secure the 339-8835 Harness and the 340-6323 Cable to the existing chassis cables using 4P-7581 Ladder Clips and 3S-2093 Cable Straps as needed. Take care to protect wires from possible damage.

NOTE: When possible follow the existing Prinoth wiring harness around the rear of the engine. Refer to image 1.6.1.

12. Connect the 340-6323 Cable to the remaining power stud on the 209-5582 Air Inlet Heater Relay. Connect the 339-8835 Harness to the coil connector on the air inlet heater relay.

13. Reinstall the electrical panel access cover.

14. Remove all lock out tag out procedures where used. Reinstall the negative battery cable.

Image1.6.1

Image1.6.2

- Tighten nut (2) to a torque of 9 +/- 1 Nm (7 +/- 1 lb ft). Hold nut (6) with an additional wrench while tightening nut (2).

- Tighten the isolation mount (5) to a torque of 12 +/- 1 Nm (9 +/- 1 lb ft).

- Tighten mounting hardware (1) to a torque of 55 +/- 9 Nm (41 +/- 7 lb ft).

NOTE: Secure the wire with the clip before applying the proper torque of 2.25 +/- 0.25 Nm (20 +/- 2 lb in) to nut (3) while holding nut (4) with a wrench.

Wire terminal nuts and locking washers are supplied with the relay. Caterpillar recommends the use of a torque wrench such as the Mountz TLS-1360 torque wrench.

NOTE: Not meeting the specified torque limit may cause electrical arcing due to a mechanical failure of the stud on the relay or a loose connection.

Group Number 2

1. Remove all power to the engine following local lock out tag out procedures. Remove power to the electrical panel by removing the negative cable from battery. Remove the air inlet heater relay assembly and all associated wiring from the current mounting point on the engine. These parts will not be reused. Refer to image 2.1.1

Image2.1.1

2. Remove the access cover from the electrical panel. Drill (2) 15mm or 9/16" diameter holes to mount rubber isolation mounts to the electrical panel. Refer to hole location template Image2.2.1 and Image2.2.2.

Note: To avoid any possibility of electrical shorts in the circuit box, be sure to clean away all aluminum chips from the drilling process.

Image2.2.1

Image2.2.2

3. Remove rubber isolation mounts from the 283-1226 Bracket. Remove the metal inserts from the isolation mounts. Insert the rubber portion of the isolation mount into the 15mm or 9/16" diameter holes in panel unitl it locks in place at the center groove. Refer to Image2.3.1. Reinstall the metal inserts from the outside of the electrical panel through the rubber isolation mounts. Refer to Image2.3.2

Image2.3.1

Image2.3.2

NOTE: The 209-5582 air inlet heater relay must be mounted inside the electrical panel for this application.

Refer to Image2.5.2 for relay nut and bolt location references and torque requirements.

4. Attach the new 209-5582 Air Inlet Heater Relay to the isolation mounts using (2) 208-9277 Bolts. Tighten the 208-9277 Bolts to a torque of 12 +/- 1 .Nm (9 +/- 1 lb ft). Remove existing air inlet heater power cable from electrical panel. This cable will not be reused.

5. Connect the 349-4777 Cable to the right wire terminal of the 209-5582 Air Inlet Heater Relay power stud. Refer to Image2.4.1. Tighten nut(2) to a torque of 9 +/- 1 Nm (7 +/- 1 lb ft). Hold nut (6) with an additional wrench while tightening nut (2) to prevent nut (6) from turning.

6. Connect the other end of the 349-4777 Cable to the air inlet heater circuit breaker power connection. Secure 349-4777 cable to existing wiring with 3S-2093 Cable Straps as needed.

Image2.4.1

7. Remove the existing cable from the air inlet heater element. This cable will not be reused.

8. Securely connect the new 349-4779 Cable and the existing Prinoth heater indicator lamp wire to air inlet heater element. Be sure good electrical connection is made by both the cable and the indicator wire. Tighten nut to a torque of 9 +/- 1 Nm (7 +/- 1 lb ft).

9. Connect the 349-4780 Harness to the air inlet heater relay control engine harness connector. Route the 349-4779 Cable and 349-4780 Harness to electrical panel.

10. Secure 349-4780 Harness and 349-4779 Cable to existing chassis cables using 4P-7581 Ladder Clips and 3S-2093 Cable Straps as needed. Take care to protect wires from possible damage.

NOTE: When possible follow the existing Prinoth wiring harness around the rear of the engine. Refer to Image2.5.1.

11. Connect the 349-4779 Cable to the remaining power stud on the 209-5582 Air Inlet Heater Relay. Connect the 349-4780 Harness to the coil connector on the air inlet heater relay. Reinstall the electrical panel access cover. Remove all lock out tag out procedures where used. Reinstall the negative battery cable.

Image2.5.1

Image2.5.2

- Tighten nut (2) to a torque of 9 +/- 1 .Nm (7 +/- 1 lb ft). Hold nut (6) with an additional wrench as you are applying torque to nut (2) .

- Tighten isolation mount (5) to a torque of 12 +/- 1 .Nm (9 +/- 1 lb ft).

- Tighten mounting hardware (1) to a torque of 55 +/- 9 .Nm (41 +/- 7 lb ft).

NOTE: Secure the wire with the clip before applying the proper torque of 2.25 +/- 0.25 Nm (20 +/- 2 lb in) to nut (3) while holding nut (4) with a wrench.

Wire terminal nuts and locking washers are supplied with the relay. Caterpillar recommends the use of a torque wrench such as the Mountz TLS-1360 torque wrench.

NOTE: Not meeting the specified torque limit may cause electrical arcing due to a mechanical failure of the stud on the relay or a loose connection.