PRODUCT SUPPORT PROGRAM FOR REPAIRING A TERMINAL BLOCK OVERLOAD AND POTENTIAL WIRE OVERHEAT PROBLEM ON CERTAIN 3412C ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING A TERMINAL BLOCK OVERLOAD AND POTENTIAL WIRE OVERHEAT PROBLEM ON CERTAIN 3412C ENGINES

Usage:

SEBE8038-04

June 30, 2002
(Revised November 2002)
U-145
A-107
O-121

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPAIRING A TERMINAL BLOCK OVERLOAD AND POTENTIAL WIRE OVERHEAT PROBLEM ON CERTAIN 3412C ENGINES
4460		PS40901

NOTE: This Program can 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 "PS40901" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "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 Caterpillar product analyst.

NOTE: This Revised Service Letter replaces the June 30, 2002 (Revised September 2002) Service Letter. Changes have been made to the Parts Needed and the Rework Procedure.

TERMINATION DATE

June 30, 2004

PROBLEM

In certain conditions some 3412 terminal blocks (131, 132, 133) may become overloaded and the wires overheat.

AFFECTED PRODUCT

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Model	Identification Number
Parts	99Z24429
3412C	9EP176, 179, 190, 193, 196, 207, 224, 226-236, 239, 240, 251, 254, 257-260, 263, 264, 269, 285, 286, 289, 290, 298, 305, 308-310, 312-316, 322, 323, 325-328, 332, 334, 335, 347, 352, 357, 358, 360, 361, 364, 365, 373, 374, 376, 379, 381, 382, 386-388, 390, 392, 393, 401, 402, 405, 410, 417, 418, 423, 430, 435, 440, 444, 445, 450, 451, 455-457, 460, 465, 466, 469, 473, 474, 478, 479, 486-493, 495, 498, 499, 502, 503, 506-509, 512, 517, 522, 523, 527-532, 536, 538-540, 542-544, 546, 548-550, 552, 553, 555-570, 572-576, 578-580, 582, 584, 586-588, 590-592, 594-596, 598, 599, 601, 602, 604-606, 608, 611, 612, 614, 615, 619, 621-625, 629, 631, 632, 644, 645, 647, 652, 654, 656, 660, 664-667, 676, 677, 679, 680, 682, 688, 692, 695, 699-701, 710, 722, 723, 726, 728, 730, 733, 734, 742, 744-746, 754, 757, 765, 767, 768, 771-775, 779, 785, 786, 788, 790, 791, 793, 794, 801, 804, 806, 809-811, 814, 815, 822, 824, 825, 828, 829, 831, 837, 843, 844, 848, 849, 852, 855, 859-861, 865, 867, 869-871, 874, 878, 882-884, 886, 888, 892, 893, 897, 898, 900, 902, 911, 917, 919, 920, 923-925, 929, 930, 952, 955, 964, 965, 968, 971, 973-975, 991, 992, 995, 1011-1013, 1027-1030, 1046-1049, 1063, 1069-1072, 1083-1085, 1091, 1093, 1115-1119, 1122, 1125, 1127, 1139, 1140, 1143, 1147, 1148, 1150, 1158, 1161, 1166, 1173-1175, 1189, 1209, 1230, 1246, 1260, 1275, 1301, 1302, 1310, 1311, 1313, 1317, 1318, 1321-1328, 1349, 1358, 1365, 1375, 1376, 1382, 1384, 1387-1389, 1395, 1396, 1400, 1406, 1407, 1414, 1416, 1421, 1422, 1426-1428, 1438-1441, 1443, 1445, 1452-1455, 1459, 1461-1463, 1465, 1471, 1481, 1484-1493, 1504-1506, 1510-1512, 1515, 1517, 1519, 1522-1524, 1530, 1535-1537, 1539-1541, 1548, 1552-1555, 1557-1561, 1573, 1574, 1579, 1583, 1584, 1586, 1588-1591, 1595, 1598, 1600-1603, 1605-1609, 1611, 1615, 1617-1621, 1623, 1626, 1630-1632, 1636-1642, 1644, 1646, 1647, 1649-1651, 1653, 1654, 1656, 1658-1659, 1661-1663, 1666-1668, 1670, 1671, 1674, 1675, 1680, 1682-1684, 1686, 1689, 1694, 1695, 1697, 1698, 1700-1703, 1705, 1707-1709, 1711, 1713, 1714, 1719, 1722, 1724, 1725, 1727, 1733-1736, 1738-1742, 1744, 1750-1752, 1754-1757 BCW132, 143-147, 155-158, 162, 168, 169, 172-175, 177, 180, 181, 184, 186, 189, 192, 200, 201, 203-205, 208, 214, 216-219, 226, 231, 233, 239, 240-243, 247-249, 251, 253, 258, 261-264, 273, 280-282, 284-286, 296, 297, 299, 305, 306, 313, 314, 323, 324, 327, 341, 348, 350, 353-356, 360-372, 375, 376, 379-381, 383-385, 391-395, 399-402, 404, 406-408, 410-412, 418, 421, 425-427, 429, 430, 433, 435, 436, 440, 441, 443-447, 450, 451, 454, 457-459, 463, 464, 466, 467, 469, 479, 480, 482-484, 487, 490, 492-496, 502, 504, 505

PARTS NEEDED

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Qty	Part Number	Description
1	3E5503	Bar
1	1096539	Plate
11	1735411	Block-Termin
2	1748737	Bar-Fixed Br
2	1894769	Block-Termin
1	1967750	Marker Kit
1	2053616	Bridge-Step
1	2181958	Harness As

ACTION REQUIRED

See the attached Rework Procedure.

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
0-36 mos	100%	3.5	0	0	0	0
NOTE: This is a 3.5?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Turn off all supply power, prevent the engine from starting and lock out the equipment before working on the equipment or inside equipment.

Only qualified Caterpillar technicians must service this equipment.

Always use the properly rated voltage-sensing device in order to confirm power is off.

Replace all devices, doors, and covers before turning power on to this equipment.

Observe all safety procedures as indicated in Caterpillar manuals.

Disconnect all wires going to terminal blocks 131, 132, 133, 139, 148, and the ground wire. These terminal blocks are located in the marshaling box on the top portion of the Box as shown in Illustration A.
Remove the terminal blocks 131, 132, 133, 139, and the ground wire.
Install the new terminal blocks in the appropriate locations as shown in Illustration B and described in the following text.

Illustration A

Install two 1894769 terminal blocks for TB (131). Install six 1735411 terminal blocks for TB (132, 133, 133, 139, 148, and GND).

Illustration B

Install a total of two 2053616 Step Down Jumpers one between existing smaller TB 132 to the new larger TB 132 1735411 and also one between existing smaller TB GND to the new larger TB GND 1735411. Install a 1748737 spacer under the 2053616 in the terminal block. Attach the 2053616 jumper with the terminal block screw through the spacer 1748737 therefore insuring a complete sound connection to the terminal block.
Install one 1748737 jumper across the two TB 133?s.
Install one 1096539 plate between TB 132 and TB 133.
Install one 3E5503 jumper across the two TB 131?s.
Connect all existing wires going to the bottom part of the terminal blocks. Install the new 8 AWG wires that will run from the top terminal blocks 132, 133, and GND to the bottom of the marshaling box. Route the new wires along the wireway with the other wires until the wires end up at the bottom of the marshaling box.
Remove the 5 terminal blocks 132, 131, 133, GND, GND and replace with the new 1735411 TB.

Illustration C

Install one 1748737 Jumper across TB GND.
Connect the new 8 AWG wires onto the TB in the lower portion of the marshaling box in the appropriate locations as shown in Illustration C.