PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHASSIS WIRING HARNESS ON CERTAIN D8T TRACK-TYPE TRACTORS Caterpillar


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PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHASSIS WIRING HARNESS ON CERTAIN D8T TRACK-TYPE TRACTORS [UEBE1329]
ELECTRICAL AND STARTING SYSTEM
WIRING GP
UEBE1329-00

11Nov2020


U-660
A-543
D-622
O-612

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHASSIS WIRING HARNESS ON CERTAIN D8T TRACK-TYPE TRACTORS

1408
PS46913
NOTE:

AVSpare’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 AVSpare.

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 "PS46913" 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.

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.


TERMINATION DATE

30Nov2022

PROBLEM

The existing chassis harness may interfere with other harnesses or components on the D8T Track-Type Tractors. Updating the harness routing hardware will address these issues.

AFFECTED PRODUCT

Model Identification Number
D8T  AW400316, 318-1185

PARTS NEEDED

Qty

Part Number Description
3 1S0994 CLIP-LOOP
1 2V1771 GROMMET
1 3U2428 CLIP-LOOP
4 8T4121 WASHER-HARD
1 8T4136 BOLT-HEX HEAD
2 1305300 CLIP
2 1336934 SPACER-HARD
1 1769237 STUD-BOLT
1 2048000 MOUNT-TIE WRAP
1 3039449 STUD-BOLT
20 3114859 TUBE BK-ELEC
2 3445675 NUT-HEX
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 10% 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

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-5000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
5001-7500 hrs,
37-54 mo 
33.0%
50.0%
0.0%
0.0%
50.0%
50.0%
 NOTE: This is a 4.0-hour job
An additional hour of labor is allowed after-failure when repairs to the harness are required.



PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
 


Rework Procedure


 
NOTE: Steps 1-8 cover updates to the chassis harness under the cab. Damage to wiring at this location may cause the machine to exhibit codes related to Cat Grade Control, among other codes.

1. Remove the floormat and floorplate from the cab in order to access the harness. Refer to the following:

Disassembly and Assembly
D8T Track-Type Tractor Machine Systems
Media Number - M0089454
 
2. Locate the chassis harness below the floorplate, on the left side toward the front, closer to the engine. The images below show the chassis harness, as well as other optional harness that may be present. These additional harnesses can make it more difficult to route all harnesses without interference. Interference can be between the harnesses themselves, or between the harness(s) and the fuel tube (red) assembled over flywheel housing, left side of engine.


- Image 1.2.1 shows the chassis harness (black arrow) and fuel tube (white arrow)
- Image 1.2.2 adds the ARO harness (white arrow)
- Image 1.2.3 adds the powered bottom guard (PBG) harness (white arrow)
Image1.2.1
Image1.2.2
Image1.2.3
 
3. Inspect harness in the designated location. If braid is damaged, wrap the harness with tape and proceed with new hardware and harness routing.

NOTE: If wires are damaged, refer to REHS7215 for repair procedures.
 
4. Install new hardware as shown in Images 1.4.1 and 1.4.2. Shown without wiring harnesses for clarity. It will be necessary to include the chassis harness in the p-clip when installing.

- 8T-4121 Washer (1)
- 176-9237 Stud-bolt (2)
- 204-8000 Mount (3)
- 3U-2428 P-clip (4)
- 344-5675 Nut (5)
Image1.4.1
Image1.4.2
 
Image 1.5.1 below shows the updated routing of the chassis harness with the new hardware. The new hardware should improve clearance to the fuel tube at the location inside the white circle.
Image1.5.1
 
5. Route the optional ARO harness (if equipped) as shown in Image 1.6.1 below, securing it with zip ties to the 204-8000 Mount at the arrow.
Image1.6.1
 
6. Route the optional PBG harness (if equipped) as shown in Image 1.7.1 below. Secure it to the chassis harness with zip ties, as marked by the arrows.
Image1.7.1
 
7. Images 1.8.1 and 1.8.2 both show the updated harness routing on a machine equipped with the standard chassis harness as well as the ARO harness. Add an additional zip tie as shown at the red arrow in both images to ensure the harnesses are secure. If the machine is also equipped with a PBG harness, it may be necessary to zip tie it as well.
Image1.8.1
Image1.8.2
 
8. Ensure all wiring harnesses have adequate clearance to any adjacent components, then re-install floorplate in cab before moving on to the next part of the harness rework.
 
NOTE: Steps 9-17 cover updates to the fender harness near the Ground Level Service Center. If damage to wiring occurs at this location, it may not be possible to shut the machine down with the master disconnect switch.

9. Remove sheet metal components on the left fender/battery box area. The red circle in Image 1.10.1 shows where the new hardware will be used.
Image1.10.1
 
10. With the sheet metal covers removed, note the ground cable running to the back side of the master disconnect switch. This cable may be damaged at the location marked with a red arrow in Image 1.11.1 below, where a bolt sticks through a weld nut. If insulation is damaged, disconnect cable, then use heat shrink tubing (311-4859 Tube) to cover the exposed portion.
Image1.11.1
 
11. To address the issue shown in Step 10 above, the hardware inside the left-hand circle in Image 1.12.1 below will be updated. The wire terminal that connects to the master disconnect, shown inside the right-hand circle, will be flipped upside down. See the following steps for details.
Image1.12.1
 
12. Install new hardware as shown in Image 1.13.1. Note that there are two 130-5300 Clips that are installed facing opposite directions from each other.

- 8T-4121 Washer (1)
- 133-6934 Spacer (2)
- 130-5300 Clip (3)
- 303-9449 Stud Bolt (4)
Image1.13.1
 
13. Install hardware used to mount ground cable as shown in Image 1.14.1 below. Hardware shown without ground cable for clarity. Be sure to install cable in grommet and p-clip before installing nut.

- 8T-4121 Washer (1)
- 1S-0994 P-Clip (2)
- 2V-1771 Grommet (3)
- 344-5675 Nut (4)
Image1.14.1
 
14. With hardware installed, ensure wiring harness connectors are secured to 130-5300 Clips, as shown in Image 1.15.1 below.
Image1.15.1
 
15. If the machine is equipped with powered bottom guards, Install mounting hardware as shown in Image 1.16.1 below. Re-use existing bracket (A), along with P-Clips (1) and Bolt (2).

- 1S-0994 P-Clip (1)
- 8T-4136 Bolt (2)
- Existing Bracket (A)
Image1.16.1
 
16. Re-attach ground cable terminal to master disconnect switch, rotating it 180 degrees from its original position. This will adjust the position of the cable to eliminate risk of it rubbing on the bolt discussed earlier in this procedure. Refer to Image 1.17.1.

Once the cable is secured, position rubber boot to cover the connection.
Image1.17.1
 
17. Ensure all wires are routed properly with all objectionable contact eliminated. Re-install all covers that were removed as part of this rework procedure before the machine is returned to service.
 
 

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