PRODUCT SUPPORT PROGRAM FOR REWORKING 418-9305 ELECTRICAL HARNESS TO LOCK THE ENGINE REMOTELY AND TO REPLACE THE 397-3656 FUSE/RELAY FILM ON CERTAIN 307E MINI EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING 418-9305 ELECTRICAL HARNESS TO LOCK THE ENGINE REMOTELY AND TO REPLACE THE 397-3656 FUSE/RELAY FILM ON CERTAIN 307E MINI EXCAVATORS

Usage:

REBE9444-00

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28Mar2013

D-110

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING 418-9305 ELECTRICAL HARNESS TO LOCK THE ENGINE REMOTELY AND TO REPLACE THE 3973656/">397-3656 FUSE/RELAY FILM ON CERTAIN 307E MINI EXCAVATORS
1408 7405		PS52416

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52416" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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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TERMINATION DATE

31Mar2014

PROBLEM

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The existing 418-9305 Electrical Harness is unable to lock up the engine remotely on certain 307E Mini Excavators. If the existing 418-9305 Electrical Harness has been re-worked, the engine will be able to remotely lock-up using GPS activation. It is also required that a new revised 3973656/">397-3656 Fuse/Relay Film be installed. The revised 3973656/">397-3656 Fuse/Relay Film will be completed with a glow plug symbol.

AFFECTED PRODUCT

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Model	Identification Number
307E	H1Y00100-00135

PARTS NEEDED

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Qty	Part Number	Description
3	1364878	SPLICE-WIRE
1	3973656	FILM-FUSE/RELAY
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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.

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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%
0-1200 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-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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Refer to your machine Operation and Maintenance Manual and your Service Manual for all safety information before completing this Rework Procedure.

1. Turn the disconnect/isolator switch to the OFF position.

2. Remove the disconnect/isolator key.

3. Ensure that the engine will not run or startup.

4. Put up notification in order to alert that the machine is being reworked.

5. Open the electrical fuse box cover. The fuse box cover is located under the seat. Refer to Image1.1.1.

6. Unbolt the fuse box mounting screws and remove the complete fuse box. Refer to Image1.2.1.

Image1.2.1

7. Unclip the relay base socket located at the four locations shown in Image1.3.1.

8. Remove the relay base socket from the fuse box assembly.

Image1.3.1

9. Locate the following cables:

Cable Number: P977 (pink cable)
Cable Number: C904 (green cable)
Cable Number: 307 (orange cable)

10. Join the cables as stated below. Refer to Image1.4.1.

Cable Number: C904-A75 to join with P977-A90
Cable Number: 307-A45 to join with C904-A75
Cable Number: P977-A90 to join with 307-A45

Image1.4.1

11. Cut the selected cables and remove a section of the insulation. Retain the section of insulation for later reuse in this Rework Procedure. This will be used in order to re-join the cables and for soldering work. Refer to Image1.5.1.

Image1.5.1

12. Insert a 136-4878 Wire Splice into one end of the cut cable. Refer to Image1.6.1.

13. Join and solder the cables accordingly.

Note: Refer back to Image1.4.1 for the details in order to re-join the cables. Completed cable re-soldering is shown in Image1.6.2.

Note: Refer to Image1.6.3 for the completed cable wire splice rework.

Image1.6.2

14. Assemble the relay base socket onto the fuse box assembly. Refer to Image1.7.1.

15. Assemble the fuse box. Refer to Image1.7.1.

16. Bolt the fuse box and the cover. Refer to Image1.7.2

Note: The electrical harness Rework Procedure is completed.

Image1.7.1

Image1.7.3

Revised Fuse/Relay Installation

1. Remove the old fuse film on the fuse box cover. The fuse box cover is located below the cab seat. Refer to Image1.8.1.

2. After removal of the old fuse film, clean the fuse film decal surface thoroughly.

3. Install the new 3973656/">397-3656 Fuse/Relay Film onto the fuse box cover. Refer to Image1.8.1.

4. Clean the new 3973656/">397-3656 Fuse/Relay Film.

Note: The fuse/relay film Rework procedure is completed.