PRODUCT SUPPORT PROGRAM FOR REWIRING THE BEST BATTERY SYSTEM ON 3516B ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWIRING THE BEST BATTERY SYSTEM ON 3516B ENGINES

Usage:

SEBE8550-01

October 24, 2003
(Revised November 2003)
U-293

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REWIRING THE BEST BATTERY SYSTEM ON 3516B ENGINES
1453		PS41461

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 "PS41461" 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 October 24, 2003 Service Letter. Changes have been made to the Parts Needed.

TERMINATION DATE

October 31, 2005

PROBLEM

The best battery system needs to be rewired on certain 3516B engines. The system consistently uses only one starter to crank the engine. The excessive loading on this starter could lead to its premature failure

AFFECTED PRODUCT

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Model	Identification Number
3516B	6HN832, 835, 838, 844, 845, 850, 853, 855-857, 865, 869, 870, 873, 879, 880, 887, 895, 897, 908, 912, 913, 915-918, 922, 1017, 1031, 1034, 1037, 1040, 1047, 1048, 1055, 1103, 1104, 1251, 1254-1257, 1260-1264, 1295, 1296, 1310, 1314, 1506

PARTS NEEDED

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Qty	Part Number	Description
1	4D6066	STRIP
10m	5P5622	WIRE
10m	5P5624	WIRE
1	5P2566	BOLT
1	6V8188	NUT

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product age	Caterpillar		Dealer Suggested		Customer Suggested
Product age	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-48 mos	100%	2.0	0	0	0	0
NOTE: This is a 2.0?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 or inside equipment. Only qualified Caterpillar technicians must service this equipment. Always use properly rated voltage sensing to confirm power is off. Replace all devices, doors, and covers before turning power on to the equipment. Make sure the technician uses the heat detection device in order to ensure that the muffler and radiator are cool enough to work around. Observe all safety procedures as indicated in Caterpillar manuals. For all wiring performed in the following procedure refer to print 1973177 Rev 01.

Remove the following wires from the top starter positive post on the left side of the engine: remove wire numbers 101, 124 and 150.
Isolate the wires 101, 124, and 150 from the battery cable. Connect them together with a 1/2" nut and bolt and insulate.
Remove the wires between the starter solenoid PS1 and the contactors C1 and C2. These wires are located on the left side of the unit between the best battery contactors and the starter.
Remove the wires between the starter solenoid PS2 and the contactors C3 and C4. These wires are located on the left side of the unit between the best battery contactors and the starter.
Remove the #10 AWG wires BC1/B- from C1 and BC2/B- from C3.
Add a #10 AWG wire from BC1/B- to the starter negative battery post.
Add a #10 AWG wire from BC2/B- to the starter negative battery post.
Disconnect wire TB14 from SMMS1 in the EMCP and leave for use in step 15.
Disconnect wire TB15 from SMMS2 in the EMCP and leave for use in step 16.
Connect the #14 AWG wire from SMMS1 to TB5.
Connect the #14 AWG wire from SMMS1 to TB5A.
Run two additional wires from the EMCP to the distribution panel. In the distribution panel, connect one wire to the positive terminal on starter contactor C1 and the other to the positive terminal on starter contactor C3.
Add strip terminal (4D6066) beside the SMMS1 and SMMS2 in the EMCP (use self taping sheet metal screws). Refer to Illustration 1.

Illustration 1 ? Terminal Strip Location in EMCP

Connect the other end of the wire attached to the positive terminal on starter contactor C1 to the terminal strip (4D6066).
Connect the loose end of wire TB15 that came off SMMS2 (step 9) to the terminal strip (4D6066) in the EMCP below the connection made in step 14. This should make a connection between wire TB15 and the positive terminal on C1.
Connect the other end of the wire attached to the positive terminal on starter contactor C3 to the terminal strip (4D6066).
Connect the loose end of wire TB14 that came off SMMS1 (step 8) to the terminal strip (4D6066) in the EMCP below the connection made in step 16. This should make a connection between wire TB14 and the positive terminal on C3.
Move wire CB31/17 termination from terminal #17 to blank terminal #16 inside the distribution panel. See Illustration 2.