2003/03/24 A New Electronic Controller for the Air Inlet Heater Improves the Engine Starting Ability {1090} Caterpillar

A New Electronic Controller for the Air Inlet Heater Improves the Engine Starting Ability {1090}

2003/03/24 [SEPD0676]

2003/03/24 Special Instruction, REHS1578, "Installation Instructions for the 9W-1494 Service Meter Kit " Is Available {7478}

2003/03/24 New Flash Software Allows Calibrations of the Power Train to be Performed by Using the Caterpillar Electronic Technician {0783, 0785, 7620}

Excavator:
322B (S/N: 1AS1-UP; 8MR1-UP; 3NR1-UP; 5CR1-UP; 1ZS1-UP; 2ES1-UP)
322B L (S/N: 1YS1-UP; 8NR1-UP)
322C (S/N: BPH1-UP; BKJ1-UP; BFK1-UP; BKM1-UP; CAM1-UP; BFN1-UP; BLP1-UP; BGR1-UP; BFX1-UP; BMX1-UP; SLX1-UP; BNY1-UP; CBY1-UP)
325B (S/N: 8GM1-UP; 6DN1-UP; 7EN1-UP; 8FN1-UP; 4DS1-UP; 5BS1-UP; 8PR1-UP; 8RR1-UP)
325B L (S/N: 1GS1-UP; 2JR1-UP)
M325B (S/N: BGN1-UP)
Asphalt Paver:
AP-1000B (S/N: 7HN1-UP)
AP-1050B (S/N: 6ZN1-UP)
AP-1055B (S/N: ABB1-UP; 8BM1-UP)
AP1055B (S/N: AGB1-UP)
BG-2455C (S/N: ACM1-UP; 6TN1-UP)
BG-245C (S/N: 4XN1-UP)
BG-260C (S/N: 8GN1-UP)
Knuckleboom Loader:
539 (S/N: 1PZ1-UP)
Forwarder:
1088XLC (S/N: 9BW1-UP)
574 (S/N: 1FM1-UP)
Wheel Feller Buncher:
533 (S/N: CDR1-UP)
543 (S/N: ASJ1-UP)
TK370 (S/N: WBD1-UP)
TK380 (S/N: WBE1-UP)
Wheel Harvester:
487 (S/N: 6KW1-UP)
495 (S/N: 5TZ1-UP)
550 (S/N: 7ZN1-UP)
570 (S/N: 4XR1-UP)
580 (S/N: 7CN1-UP)
687 (S/N: 4FZ1-UP)
695 (S/N: 8MW1-UP)
Integrated Toolcarrier:
IT38G (S/N: 7BS1-UP; 1CW1-UP)
IT62G (S/N: AKP1-UP; 6PS1-UP)
Wheel Loader:
938G (S/N: 4YS1-UP; 6WS1-UP; 8RS1-UP; 9HS1-UP)
950F Series II (S/N: 5SK1-UP; 8TK1-UP; 2LM1-UP)
950F (S/N: 7ZF1-UP; 6YG1-UP; 4DJ1-UP)
950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)
960F (S/N: 9ZJ1-UP; 6XL1-UP; 1YM1-UP)
962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)
Wheel Skidder:
525B (S/N: 3KZ1-UP)
535B (S/N: AAE1-UP)
Wheel Tractor-Scraper:
613C Series II (S/N: KEH1-UP; 8LJ1-UP)
Service Magazine SEPD0676, 24 March 2003, "A New Electronic Controller for the Air Inlet Heater (AIH) Improves the Engine Starting Ability". Disregard this article. See the article that follows.

Description of Change: A new electronic controller improves the engine starting ability. The electronic controller regulates the controlling cycle of the AIH. The AIH is an engine starting aid. Control of the heating cycle helps eliminate excessive white smoke at start-up.

Adaptable To: The new 197-4330 Air Controller replaces the former 104-3204 Air Controller. The new electronic controller for the AIH is effective with the machines that are listed in Table 1. The new controller is adaptable to the models that are listed.

The new components in the air inlet heater arrangement are listed in Table 2. The location of the new controller is shown in Illustration 1. The procedure for the assembly of the new components is included in this article.

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Table 1
Effectivity Of The New 197-4330 Air Controller
Model	Effectivity	Adaptability
322B L	S/N:1YS1616-UP	S/N:1YS1-1615
325B	S/N:8PR381-UP	S/N:8PR1-380
325B L	S/N:2JR3324-UP S/N:8RR615-UP S/N:1GS159-UP	S/N:2JR1-3323 S/N:8RR1-614 S/N:1GS1-158
M325B	S/N:BGN303-UP	S/N:BGN1-302

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Table 2
Changes To The Air Inlet Heater Arrangement For 320B And 320C Excavators
Qty	New Part Number	Description	Former Part Number
1	197-4330	Air Controller	104-3204
1	168-5057	Air Inlet Heater	5I-7746
1	197-4436	Starting Aid Harness As	-
Changes To The Air Inlet Heater Arrangement For 322B, 325B, and M325B Excavators
1	197-4330	Air Controller	104-3204

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Illustration 1	g00791997
Typical View of the Control Panel Without the Panel Door (A) 197-4330 Air Controller (B) Safety Device for the Starting Aid Relay (C) 12-pin Connector (D) 306-Green Wire (E) 3S-2093 Cable Strap (F) Wiring Harness Assembly (G) Connector for the Electrical Control of the AIH

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Illustration 2	g00792610
View A-A from Illustration 1 (B) Safety Device for the Starting Aid Relay

Procedure For the Installation of the New 197-4330 Air Controller in 320B Excavators

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Table 3
Required Parts For 320B Excavators
Qty	Part Number	Description
1	197-4330	Air Controller
1	168-5057	Air Inlet Heater
1	197-4436	Starting Aid Harness As
6	3S-2093	Cable Strap

Procure the parts that are listed in Table 3. The locations of the components are shown in Illustration 1 and Illustration 2.

Disassemble connector (G) from the 104-3204 Air Controller .

Remove the former 104-3204 Air Controller from the control panel.

Install the new 197-4330 Air Controller in place of the former electronic controller.

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Illustration 3	g00793392
Wiring Schematic For The AIH

Assemble connector (G) to the new 197-4436 Starting Aid Harness As. Refer to the wiring schematic that is shown in Illustration 3.

Install the wire harness with connector (G) to the new controller.

Disassemble connector (B) from the former wire harness.

Assemble connector (B) to the new 197-4436 Starting Aid Harness As .

Install the wire harness with connector (B) to the safety device for the air heater relay.

Install the wire harness at the 12-pin connector (C) .

Install the 306-Green Wire into pin location 5 of the 12-pin connector (C) .

Secure the new wire harness with the new cable straps (E) .

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Illustration 4	g00797601
Location of the Air Inlet Heater (J) 168-5057 Air Inlet Heater

Remove the former 5I-7746 Heater As from the air intake manifold. The location of the air inlet heater is shown in Illustration 4. Install the new 168-5057 Air Inlet Heater .

Procedure For the Installation of the New 197-4330 Air Controller in 322B, 322B L, 325B, 325B L, and M325B Excavators

Procure a 197-4330 Air Controller. The location of the electronic controller is shown in Illustration 1.

Disassemble wire harness connector (G) from the 104-3204 Air Controller .

Remove the electronic controller from the control panel.

Install the new 197-4330 Air Controller in place of the former electronic controller.

Assemble the wire harness connector to the new electronic controller.

Procedure For the Installation of the New 197-4330 Air Controller in 320C Excavators

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Table 4
Required Parts For 320C Excavators
Qty	Part Number	Description
1	197-4330	Air Controller
1	168-5057	Air Inlet Heater
1	197-4436	Starting Aid Harness As
5	3S-2093	Cable Strap

Procure the parts that are listed in Table 4. The locations of the components are shown in Illustrations 5, 7, and 8.

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Illustration 5	g00986435
Typical View of the Control Panel Without the Panel Door (A) 197-4330 Air Controller

Disassemble connector (G) from the 104-3204 Air Controller .

Remove the former 104-3204 Air Controller from the control panel.

Install the new 197-4330 Air Controller in place of the former electronic controller.

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Illustration 6	g00986433
Wiring Schematic for the AIH

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Illustration 7	g00986437
View K-K of the Control Panel (A) 197-4330 Air Controller (G) Connector for the Electrical Control of the AIH

Assemble connector (G) to the new 197-4436 Starting Aid Harness As. Refer to the wiring schematic that is shown in Illustration 6.

Install the wire harness with connector (G) to the new controller.

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Illustration 8	g00986467
View L-L of the Control Panel (B) Safety Device for Starting Aid Relay (M) Electrical Connector

Disassemble connector (M) from the former wire harness.

Assemble connector (M) to the new 197-4436 Starting Aid Harness As .

Install the wire harness with connector (M) to the safety device for the air heater relay.

Secure the single 306-Green Wire to the new harness with the new cable straps.

Secure the new wire harness with the new cable straps (E) .

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Illustration 9	g00797601
Location of the Air Inlet Heater (J) 168-5057 Air Inlet Heater

Remove the former 5I-7746 Heater As from the air intake manifold. The location of the air inlet heater is shown in Illustration 9. Install the new 168-5057 Air Inlet Heater .