PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR INLET HEATER RELAY AND WIRING ON CERTAIN C9 TRUCK ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR INLET HEATER RELAY AND WIRING ON CERTAIN C9 TRUCK ENGINES

Usage:

REBE5452-01

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10Sep2009

(Revised 18Sep2009)

U-317

TT-39

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR INLET HEATER RELAY AND WIRING ON CERTAIN C9 TRUCK ENGINES
4493 1090		PS42965

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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 "PS42965" 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:

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 10Sep2009 Service Letter. Changes have been made to Parts Needed.

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TERMINATION DATE

30Sep2010

PROBLEM

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The air inlet heater relay can fail on certain C9 truck engines. If the relay fails the engine will be difficult to start.

AFFECTED PRODUCT

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Model

Identification Number

9DG01312-01316, 1340, 1346, 1349, 1351-1353, 1356-1362, 1364-1369, 1371-1374, 1377-1378, 1388-1400, 1408-1409, 1411-1412, 1414-1420, 1422-1426, 1428-1430, 1441-1444, 1447, 1452, 1454-1456, 1459, 1461-1463, 1473, 1498, 1530, 1533, 1536, 1548, 1552-1553, 1557, 1560, 1564, 1568-1571, 1576-1577, 1583-1595, 1599-1602, 1606-1607, 1610, 1613, 1615, 1623, 3094, 3443, 3448, 3451, 3462, 3467, 3469, 3472, 3481, 3486, 3495-3505, 3515, 3517, 3520-3525, 3527-3528, 3535, 3539, 3541, 3543, 3545-3547, 3569, 3578, 3587, 3591, 3597, 3605-3606, 3609, 3620, 3623-3625, 3629, 3644, 3647, 3663, 3667-3668, 3670, 3680, 3684-3685, 3689, 3698-3699, 3701, 3707, 3711, 3714, 3720, 3722, 3729-3730, 3735, 3745, 3821, 3961, 3984, 3988, 3996, 4011, 4023, 4053, 4057, 4062, 4065, 4068, 4073, 4082, 4084-4085, 4088, 4094, 4098, 4100, 4106, 4108-4109, 4112-4113, 4117, 4120, 4126-4128, 4135, 4137-4138, 4146-4147, 4160, 4162-4166, 4172, 4182, 4184, 4187, 4191, 4193, 4195, 4200, 4203-4206, 4217, 4222, 4261, 4264, 4271, 4277, 4319, 4329, 4341, 4350, 4360, 4364-4365, 4374, 4376-4377, 4379, 4410, 4431, 5834, 5872, 5914, 5917, 5919, 5929, 5950, 5972, 5986, 6000, 6009, 6015-6016, 6025, 6035-6036, 6039, 6044-6045, 6049, 6053, 6056, 6063, 6069, 6078, 6080, 6082, 6084, 6109, 6114, 6121, 6124, 6135-6139, 6141, 6163-6164, 6201, 6206, 6208, 6210, 6215, 6217, 6219-6220, 6222, 6225, 6228, 6236, 6239, 6249, 6251-6253, 6255, 6264-6265, 6268-6275, 6290-6294, 6302-6303, 6306, 6310-6313, 6316, 6318, 6321-6322, 6324, 6336, 6375, 6380, 6383, 6386, 6388, 6390, 6398-6399, 6401-6403, 6412, 6416, 6418-6421, 6439, 6441, 6444, 6446-6448, 6452, 6458, 6460, 6466, 6469, 6471, 6476, 6479, 6481, 6483, 6485-6486, 6488, 6490, 6495, 6501, 6519, 6522-6524, 6526-6528, 6530-6532, 6537, 6542, 6550, 6552, 6554, 6557, 6559, 6562, 6566, 6568-6569, 6571-6573, 6578, 6581, 6584, 6586-6587, 6592, 6598, 6600-6601, 6605, 6607-6609, 6611, 6618, 6626, 6630, 6634-6635, 6637-6639, 6649, 6652, 6657, 6659, 6662, 6664, 6667-6668, 6670, 6672, 6678, 6680, 6682, 6685, 6693, 6696, 6699-6700, 6702-6703, 6705, 6708, 6715, 6725, 6729, 6734, 6737, 6739-6740, 6748, 6754, 6757, 6760, 6764-6765, 6770, 6778, 6814, 6835-6836, 6858-6859, 8462, 8504, 8532, 8678, 8699, 8706, 8711, 8721, 8723-8724, 8728, 8734, 8736, 8739, 8741, 8747, 8749-8750, 8755, 8761, 8768, 8778, 8780, 8796, 8812, 9153, 9199, 9278-9279, 9290, 9316, 9323, 9337, 9343, 9377, 9383-9384, 9389-9391, 9421, 9439, 9446, 9450-9452, 9456, 9458-9460, 9462-9463, 9471-9472, 9504-9508, 9510-9513, 9518-9520, 9522-9523, 9525, 9529, 9534-9535, 9538, 9544, 9548, 9553, 9555-9556, 9559, 9563-9564, 9567, 9569-9570, 9573-9576, 9583, 9586, 9591, 9593, 9595-9596, 9602, 9612, 9624, 9637, 9639-9640, 9646, 9654, 9656, 9660-9661, 9665, 9680, 9756, 9764-9765, 9786, 9791, 9793, 9809-9810, 9812, 9815, 9840-9841, 9847, 9864, 9872, 9888-9890, 9895, 9901, 9920, 9932, 9939, 9941, 9944-9945, 9949, 9951-9952, 9955, 9958-9959, 9961, 9964-9965, 9967, 9970, 9972-9974, 9976, 9979, 9986-9989, 9994, 10001, 10003, 10024, 10042, 10054-10055, 10065, 10078, 10082, 10156, 10162, 10169, 10173, 10512, 10744

PARTS NEEDED

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Qty	Part Number	Description
6	8T4121	WASHER-HARD
1	8T4133	NUT
1	8T4182	BOLT-HEX HEAD
2	1772215	STRAP-DUAL CLAMP
2	2089277	BOLT-FLANGE HD
1	2095581	SWITCH AS-MAG
1	2831226	BRACKET AS.
1	3459109	CABLE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 30% 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 Special Instruction REHS4806 to determine if relay has failed. If the relay has failed, replace it in a new location on the truck firewall. Refer to the attached Rework Procedure for details.

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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%
0-300000 miles, 0-36 mo	100.0%	100.0%	0.0%	0.0%	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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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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1. Disconnect the positive battery connection before performing this rework procedure.

2. Remove the air inlet heater relay, the cable assembly connected to the heating element, and the relay isolation bracket assembly. These parts will not be re-used. Refer to Image1.1.1

Image1.1.1

3. Disconnect the cable connected to the starter from the air inlet heater relay. Refer to Image1.2.1

Image1.2.1

4. Relocate the air inlet heater relay to the firewall on the driver side of the engine compartment.

Refer to Image1.3.1 and Image1.3.2

Image1.3.1

Image1.3.2

5. Locate the bottom bolt of the radiator support bracket on the driver side of the engine compartment. This bolt will be used to secure the left side of the 283-1226 Relay Isolation Bracket Assembly.

6. Use the 283-1226 Relay Isolation Bracket Assembly as a template to mark the right side mounting hole. Drill a 5/16" hole for the mounting hole. Take care not to damage any components located behind the location where you are drilling the 5/16" hole. Refer to Image1.4.1

Image1.4.1

7. Use three 8T-4121 Washers on the right side of the relay isolation bracket and one 8T-4121 Washers on the left side to shim the bracket away from the firewall. Use one 8T-4182 Bolt, one 8T-4121 Washer, and one 8T-4133 Nut to secure the right side of the isolation bracket to the firewall.

Refer to Image1.5.1 and Image1.5.2

Image1.5.1

Image1.5.2

8. Remove paint or debris from the terminal lug (if necessary) then re-connect the cable connected to the starter to the 5/16" stud (2)on the right side of the 208-5581 Air Inlet Heater Relay. Use the 345-9109 Cable Assembly to re-connect the heater element to remaining 5/16" stud (1) on left side of the Air Inlet Heater Relay. Refer to Image1.6.1 and Image1.6.2

Image1.6.1

Image1.6.2

9. Reconnect relay pigtail to ECM harness connection (J501/P501).
refer to Image1.7.1

Image1.7.1

10. Secure cables as shown using the cable straps and the 177-2215 Strap Dual Clamp. The routing of the power cable should not create a force on the isolation mount on the relay. Provide relief for any items that inhibit the ability of the mounts to isolate the relay from vibration or shock. This may require additional mounting points at the relay or near the relay. A longer wire from the relay to the heater element will also remedy the issue. Power leads must be supported within six to eight inches of the terminal connection at the relay. Also, the wire must not be attached to a fuel line.

Refer to Image1.8.1

11. Reconnect the positive battery connection for the vehicle.

Image1.8.1

Torque requirements:

Wire terminal nuts and locking washers are supplied with the relay.

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.

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

Tighten isolation mount (5) to 12 +/- 1 N.m (9 +/- 1 lb ft).

Tighten mounting hardware (1) to 55 +/- 9 N.m (41 +/- 7 lb ft).

Note: Secure the wire with the clip before applying the proper torque of 2.25 +/- 0.25 N.m (20 +/- 2 lb in) to nut (3) as you are holding nut (4) with a wrench.

Refer to Image1.9.1