PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF AN ADDITIONAL RELAY AND HARNESS ON CERTAIN 216B 3 SKID STEER LOADERS (INDIA REGION ONLY) Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF AN ADDITIONAL RELAY AND HARNESS ON CERTAIN 216B 3 SKID STEER LOADERS (INDIA REGION ONLY)

Usage:

TEBE4931-00

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11Jul2016

D-320

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF AN ADDITIONAL RELAY AND HARNESS ON CERTAIN 216B 3 SKID STEER LOADERS (INDIA REGION ONLY)
7000 1408 1429		PI32659

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32659" 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 "PI32659" 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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COMPLETION DATE	TERMINATION DATE
31Jan2017	31Jul2017

PROBLEM

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The backup alarm and the reverse lights are always ON even though the machine drive joystick is returned to Neutral or when the machine is moved forward on certain 216B 3 Skid Steer Loaders. The backup alarm continuously blows and the reverse lamp remains on when the key switch is on. Installation of an additional harness and relay system will eliminate this issue.

AFFECTED PRODUCT

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Model	Identification Number
216B 3	PWK00795-00800, 1163, 1305-1308, 1338, 1380, 1383, 1385-1387, 1406, 1409-1410

PARTS NEEDED

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Qty	Part Number	Description
7	3S2093	STRAP-CABLE
7	7K1181	STRAP-CABLE
1	1151615	RELAY AS
1	1920836	SWITCH AS.
1	2584134	FUSE AS.-ROADING
1	5076719	HARNESS AS
1	5076720	HARNESS AS
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.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		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 1.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF AN ADDITIONAL RELAY AND HARNESS

MODELS INVOLVED - CERTAIN 216B 3 SKID STEER LOADERS (INDIA REGION ONLY)

Dear Cat Product Owner:

The pressure switch and relay needs to be reworked on the products listed below. The existing pressure switch and circuit can allow the reverse lights and backup alarm to remain on with machine in neutral or forward condition. You will not be charged for the service performed.

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

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 11Jul2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 11Jul2016 Service Letter

Rework Procedure

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Note: Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".

1. Position the machine on firm level ground, engage the park brake and isolate the machine.

2. Raise the lift arms (ensure no work tool attachment is available) and secure with service brace. Refer to SEBU8495, Operation and Maintenance Manual, Maintenance Section, "Loader Lift Arm Brace Operation".

3. Relieve the system pressure. Refer to UENR0252, Disassembly and Assembly, "System Pressure-Release-Hydraulic".

4. Raise the cab. Refer to SEBU8495, Operation and Maintenance Manual, Maintenance Section, "Cab Tilting".

5. Open the engine compartment door and secure the door in the open position using a 142-8832 Pin Assembly.

6. Hold the console in position with hand in order to ease the disassembly process. Disassemble the screws in sequence. Refer to Images1.2.1 and 1.2.2.

Image1.2.1

Image1.2.2

7. Remove the battery terminals using a spanner and mask both battery terminals. Ensure that proper masking is done in order to prevent the terminals from touching other parts. Refer to Image1.3.1.

Image1.3.1

8. Remove the air intake hose connected to the air cleaner as shown, by disassembling the clamp. To avoid contamination, cover the intake hose with masking tape.

9. Remove the air filter and harness connected to the air filter. Refer to Images1.4.1 and 1.4.2.

Image1.4.1

Image1.4.2

10. Cut the tie straps of the cab main harness and disconnect the cab harness from weld link using a cutter. Refer to Image1.5.1.

11. Remove the fuse cover and remove the nut and washer (circled). Refer to Image1.5.2.

Image1.5.1

Image1.5.2

12. Install a new 507-6719 Harness Assembly. Secure the harness ring terminals to the bolt in the fuse holder followed by a washer and nut.

13. Tighten the nut to a specified torque of 14 +/- 1 N.m. Refer to Image1.6.1.

Note: Ensure that the terminal faces are properly seated to avoid any discontinuity. Replace the fuse cover.

Image1.6.1

14. Identify the green tape position on the harness and secure the portion to the weld link with the platform harness using a 7K-1181 Cable Strap. Refer to Image1.7.1.

15. Route the harness assembly as shown in Image1.7.2 using a 3S-2093 Cable Strap and secure it to the engine harness near to relay with cable strap. Ensure that the harness is free from fouling and damage.

16. Secure the harness assembly to the engine harness using a 3S-2093 Cable Strap. Refer to Image1.7.3.

Image1.7.1

Image1.7.2

Image1.7.3

17. Secure the female connector of the 258-4134 Fuse Assembly to the end of the 507-6719 Harness Assembly. Refer to Image1.8.1.

18. Secure the connector to the upper frame with one 7K-1181 Cable Strap. Refer to Image1.8.2.

Image1.8.1

Image1.8.2

19. Secure the 507-6720 Harness Assembly to the male connector of the fuse assembly. Refer to Image1.9.1.

20. Secure the end connector to the weld link with one 3S-2093 Cable Strap. Refer to Image1.9.2.

Image1.9.1

Image1.9.2

21. Secure the platform harness and cab harness connectors to the weld link with two 7K-1181 Cable Straps. Refer to Image1.10.1.

22. Connect the new 115-1615 Relay Assembly to mating the connector on 507-6720 Harness Assembly. Refer to Image1.10.2.

Image1.10.1

Image1.10.2

15. Secure the relay assembly and harness assembly to the platform harness using two 3S-2093 Cable Straps. Route the remaining harness assembly along with the platform harness with cable straps. Refer to Image1.11.1.

Image1.11.1

16. Route and secure the harness assembly to weld link along with platform harness using two 7K-1181 Cable Straps. Refer to Image1.12.1.

17. Use one 3S-2093 Cable Strap to secure to the platform harness bundle. Refer to Image1.12.2.

18. Remove the nut, washer, and ground strap harness from the ground strap mounting stud using a spanner.

19. Place the ground terminal of the new 507-6720 Harness Assembly on the ground stud followed by the ground terminal of the platform harness and then washer and nut. Refer to Image1.12.3.

20. Tighten the nut to a specified torque of 30 +/- 7 N.m.

Image1.12.1

Image1.12.2

Image1.12.3

21. Replace the existing pressure switch in the CPV with a new 192-0836 Pressure Switch Assembly and then tighten the switch to 24 +/-3 N.m. Refer to Image1.13.1.

22. Secure the installed new harness male connector to the female connector in pressure switch assembly and the single cable female connector of harness to the male connector of the platform harness, which is previously connected to the pressure switch. Use one 3S-2093 Cable Strap to tie all of the connectors together and use one 7K-1181 Cable Strap to tie them back to the weld link provided in the LH joystick mounting bracket. Refer to Image1.13.2.

23. After tie back of the connectors, ensure that no bare wires touch any hydraulic lines going to LH joystick to avoid short circuit.

Image1.13.1

Image1.13.2

24. Remove the masking tape from the battery terminal.

25. Secure the negative and positive terminals to the correct battery ports. Refer to Image1.14.1.

Note: Red is positive and black is negative.

26. Route the negative cable under the positive. Ensure that the negative battery cable is routed and connected at a 45 degree angle and the terminal is seated all the way down on the battery post to avoid fouling.

27. Tighten the bolts to a specified torque of 7.2 +/- 1.6 N.m.

28. Cut all excess straps using a strap gun.

29. Install the air filter to the chassis and tighten to a specified torque of 15 +/- 3 N.m. Assemble the air filter hose to the air filter and tighten the clamp to a specified torque of 7 +/- 1 N.m.

30. Place the console in position and tighten the screws to a specified torque of 6 +/- 1 N.m using a battery gun.

31. Lower the cab. Refer to SEBU8495, Operation and Maintenance Manual, Maintenance Section, "Cab Tilting".

32. Lower lift arms. Refer to SEBU8495, Operation and Maintenance Manual, Maintenance Section, "Loader Lift Arm Brace Operation".