PRODUCT IMPROVEMENT PROGRAM FOR RETROFITTING EIS CIRCUIT BREAKER ON CERTAIN G3408C AND G3412C GAS ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR RETROFITTING EIS CIRCUIT BREAKER ON CERTAIN G3408C AND G3412C GAS ENGINES

Usage:

SEBE8313-01

March 9, 2003
(Revised April 2003)
U-65
A-51
O-61

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR RETROFITTING EIS CIRCUIT BREAKER ON CERTAIN G3408C AND G3412C GAS ENGINES
1420		PI10223

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10223" 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 "PI10223" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the March 9, 2003 Service Letter. Changes have been made to the Affected Product.

PROBLEM

The Circuit Breaker needs to be changed to a fuse holder with a ceramic fuse on certain G3408C and G3412C Spark Ignited Engines. This will bring the terminal box into certified compliance.

AFFECTED PRODUCT

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Model	Identification Number
G3408C	BAZ170, 171, 173
G3412C	6ZM164-167, 253, 255, 280, 281, 301, 303, 305, 306, 308, 309, 312, 313, 323, 334, 355-360, 362-364, 378, 382, 384, 407, 420, 454, 491, 500, 501, 502

PARTS NEEDED

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Qty	Part Number	Description
1	0365774	FUSE
1	1057543	BLOCK-FUSE

NOTE: USE ONLY CERAMIC A FUSE. (Caterpillar Inc. Part 0365774) The use of non Caterpillar Inc. approved parts will void CSA approval and could be potentially dangerous.

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	2.0	0	0	0	0
NOTE: This is a 2.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

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

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR RETROFITTING EIS CIRCUIT BREAKER

MODELS INVOLVED - CERTAIN G3408C AND G3412C GAS ENGINES

Dear Caterpillar Product Owner:

The CB-3 Circuit Breaker, inside the engine mounted terminal box, needs to be changed to a fuse holder with a ceramic fuse on the products listed below. This will bring the terminal box into CSA compliance for use in a gaseous environment. Until the circuit breaker has been retrofitted with the fuse holder and fuse DO NOT use the circuit breaker CB-3 to interrupt power to the terminal box. This could potentially result in an explosion and fire hazard. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated March 9, 2003 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to March 9, 2003 Service Letter

Rework Procedure

Locate and disconnect the source of customer?s switched power which feeds into 1141143 Circuit Breaker in the engine mounted terminal box.

NOTE: DO NOT disconnect power by switching nonconforming CB-3 (1141143) to the off position as this could generate a spark.

Remove 1141143 Breaker As. from DIN rail.

Loosen the locking screws on the DIN rail lower end block located just beneath the breaker.
Insert a 5-6 mm wide flat bladed screwdriver into the open slot on the side of the breaker and pull outward to unlatch the breaker from the DIN rail.

Unscrew the 2 screws securing the customer?s 24V DC power entering the right side of the breaker (P170-Red) and the internal harness connection (P270-Red) from the left side of the breaker.
Remove breaker and install a 1057543 Fuse block with 0365774 ceramic fuse. Check to insure the fuse block is locked onto the DIN rail and retighten the DIN rail end block at the bottom of the rail.
Reinstall the internal harness connection (P270-Red) into the left side of the fuse holder and the customer?s 24V DC power wire (P170-Red) into the right side of the fuse holder. Properly tighten both hold-down screws where the wires enter on both sides of the fuse block.
Close and secure Engine Mounted Terminal Box door and reconnect the customer?s switched power source which feeds power into new 1057543 fuse block.