PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE ELECTRICAL CONNECTOR ON THE DOSING CABINET FOR RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS EQUIPPED ON CERTAIN D399 INDUSTRIAL ENGINES, 3512C, AND C175-16 PETROLEUM ENGINES, C28 Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE ELECTRICAL CONNECTOR ON THE DOSING CABINET FOR RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS EQUIPPED ON CERTAIN D399 INDUSTRIAL ENGINES, 3512C, AND C175-16 PETROLEUM ENGINES, C28

Usage:

REBE9516-04

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22Feb2013

(Revised 09Aug2016)

U-75

A-60

D-68

O-72

TM-4

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE ELECTRICAL CONNECTOR ON THE DOSING CABINET FOR RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS EQUIPPED ON CERTAIN D399 INDUSTRIAL ENGINES, 3512C, AND C175-16 PETROLEUM ENGINES, C280-12 ENGINES, C32, 3412C, 3516B, 3516C, G3516, AND C175-16 GENERATOR SETS, PM3516, AND PM3516B POWER MODULES
108D 108H 1408		PI10920

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NOTE:

Caterpillar’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 Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10920" 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 "PI10920" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 22Feb2013 (Revised 29Jan2014) Service Letter. Changes have been made to the Parts Needed, and Action Required.

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PROBLEM

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The pin/socket gender needs to be reversed on certain dosing cabinets that are used with retrofit selective catalytic reduction systems. When the dosing cabinet is supplied with electrical power, the pin side of the connector on top of the cabinet has a 115 240 VAC potential. When the tube wire bundle is not connected to the cabinet, the energized pin is exposed and a shock hazard exists that can result in the risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3412C	DJN00518-00520
C32	JSJ00137, 861
D399	35B03380, 4355, 4717, 5366

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*****Group 2*****
3512C	LLA00170-00173, 185-188, 213-214, 349-351, 460, 463, 489, 517-518, 670, 778, 786, 788, 987, 1315-1316, 1318, 1857, 1871, 1873, 1911, 1918, 1935, 2667, 2672, 2675, 2891, 2896, 2902, 3582, 3589, 3591 SLM00109, 125, 132, 178
3516B	6HN00488, 1669 ZAR00119-00124
3516C	SBJ00605-00606, 608-609, 626, 629
C175-16	P6L00142-00145 WYB00434-00454, 456-574, 576-618
C280-12	TSJ00104-00107
G3516	ZBA01223-01224
PM3516	KEN00119
PM3516B	BPD00175, 177

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
15	8T8729	PIN-CONNECTOR
15	8T8730	SOCKET-CONNECTOR
20	8T8737	PLUG-SEAL
1	3112813	SEAL
1	3198101	RECEPTACLE-CONN
1	3907056	INSULATOR-CABLE
1	4336455	PLUG AS-CONN
1	PIGTAIL	HEAT TRACE PIGTAIL-if needed (see Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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.
*****Group 2*****
15	8T8729	PIN-CONNECTOR
15	8T8730	SOCKET-CONNECTOR
20	8T8737	PLUG-SEAL
1	3112813	SEAL
1	3198101	RECEPTACLE-CONN
1	3907056	INSULATOR-CABLE
1	4336455	PLUG AS-CONN
1	PIGTAIL	HEAT TRACE PIGTAIL-if needed (see Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

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MODEL INVOLVED - Dosing Cabinets
Factory Serial Numbers : 21002 - 23154

Safety:
Repairs to the Cabinet's electrical system will be performed in this procedure.

Parts:
The following parts are not ordered through the Morton parts system. Parts are ordered by contacting Thomas Manning (Tier 2 DSN Afterteatment)
Email - manning_thomas_w@cat.com
Telephone - 309-578-3812

QTY PART

1 HEAT TRACE PIGTAIL - ONLY NEEDED WHEN DEF LINE INCLUDES HEAT TRACE

Prior to Disassembly:
Remove/Turn off all power to the dosing cabinet.

Lock Out and Tag Out the master disconnect.
Follow all mandated safety rules.

Inspect the dosing cabinet in order to determine if the cabinet requires Deutsch plug and receptacle gender change. Image 2 shows a first run installation of connector plug and receptacle. Image 3 shows current production of connector plug and receptacle. If the dosing cabinet has current production connector, Image 3, no further action is required. If the dosing cabinet is equipped with first run connector receptacle, Image 2 please refer to the attached Rework Procedure.

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Image1

Image2

Image3

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
South America

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.5-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.5-hour job for Group 2

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PARTS DISPOSITION

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

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE ELECTRICAL CONNECTOR ON THE DOSING CABINET FOR RETROFIT SELECTIVE CATALYTIC REDUCTION SYSTEMS EQUIPPED ON CERTAIN D399 INDUSTRIAL ENGINES, 3512C, AND C175-16 PETROLEUM ENGINES, C280-12 ENGINES, C32, 3412C, 3516B, 3516C, G3516, AND C175-16 GENERATOR SETS, PM3516, AND PM3516B POWER MODULES

MODELS INVOLVED - CERTAIN D399 INDUSTRIAL ENGINES, 3512C, AND C175-16 PETROLEUM ENGINES, C280-12 ENGINES, C32, 3412C, 3516B, 3516C, G3516, AND C175-16 GENERATOR SETS, PM3516, AND PM3516B POWER MODULES, Dosing Cabinets Factory Serial Numbers: 21002 - 23154

Dear Caterpillar Product Owner:

The pin/socket gender needs to be reversed on certain dosing cabinets that are used with retrofit selective catalytic reduction systems. When the dosing cabinet is supplied with electrical power, the pin side of the connector on top of the cabinet has a 115 ? 240 V/ac potential. When the tube wire bundle is not connected to the cabinet, the energized pin is exposed and a shock hazard exists that can result in the risk of personal injury or death. You will not be charged for the rework 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 xxXxx2013 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 xxXxx2013 Service Letter Please refer the dealer to their Service Letter dated 22Feb2013 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 22Feb2013 Service Letter

Rework Procedure

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INSPECTION/REWORK PROCEDURE

Prior to any disassembly, visually inspect the Dosing Cabinet to verify rework procedure is required. If rework procedure is not required, please record in SIMS that inspection has been completed and no action is required.

23 Pin Connector Removal

Secure connector at the bottom
Loosen the jam nut on top
Remove connector through the bottom.

Image1.1.1

All wires need to be removed from the 23 pin Connector, followed by replacement of pin sockets and connector body. Using the pin removal tool, push the tool, until a slight click and the tool has bottomed out inside the connector. Grabbing each individual wire, pull the wire and the tool will follow. It is advisable to remove one group of wires at a time.

Wire pair description:
Two NOx sensors
Tube wire bundle
K Type Thermocouple
Below are the wiring colors and location.

NOx Sensor In ? Outer ring of connector CAN BUS #0
CAN + = RED WIRE = R Location connector
CAN - = WHITE WIRE = S Location connector
CAN V+ = BLUE WIRE = T Location connector
CAN RET = BLACK WIRE = U Location connector

NOx Sensor Out ? Outer Ring of connector CAN BUS #1
CAN + = RED WIRE = M Location connector
CAN - = WHITE WIRE = N Location connector
CAN V+ = BLUE WIRE = O Location connector
CAN RET = BLACK WIRE = P Location connector

K Type Thermocouple
YELLOW WIRE = C Location connector
RED WIRE = D Location connector
Twisted Ground Wire = A Location connector

Heat trace wiring

BLACK WIRE = G Location connector
WHITE WIRE = H Location connector
GREEN WIRE = J Location connector

CAN BUS #0 = Q Location connector = Pre NOx
CAN BUS #1 = V Location connector = Post NOx

Optional Communications Wire:
On the 23 pin connector there is the possibility of a 5th wire (brown).

If this wire is present, move this wire to the correct location in the new connector. Review the illustration below.

Image1.2.1

Remove one bundle of wires at a time.
Start with M, N, O and P CAN BUS #0 NOx sensor, they are in their own wire bundle. Remove all the sockets from the wires and replace with pins. After correct pins are installed on the wiring, reinsert the correct wire with pin back into new connector with corresponding location. Continue this process with the remaining pairs of wires until the connector is populated; after the wires have been installed, Install
8T-8737 Plugs in remaining open locations.

Note: These connectors are not water tight, however they are water resistant. Water or urea will still travel past the connector if the dosing cabinet is not shielded from outdoor elements or indoor moisture condensation.
Below are examples of completed procedure.

After verifying connector is assembled correctly, reverse the process for re-assembly.

Image1.3.1

The following schematic will also assist with successful re-wiring of the connector.

Image1.4.1

Tube Wire Bundle
Changing the Socket to the Plug

TWB Socket Plug Removal:
With the socket plug removed, unscrew the wedge cap and wire protector. Expose the wires inside the socket plug to verify wire layout inside the plug.
Remove the wires in the center first to expose the wire on the outer circle.
Remove C and D (Thermocouple wires) then F, G and H 120VAC wires by removing these wires
first. There will be plenty of room to get the Deutsch pin removal tool inside the connector along the rim.

If needed, mark the Pre and Post NOx sensor wires before removing each wire bundle.

Image1.5.1

The Tube Wire Bundle (TWB) was originally fitted with a female connector mated to the male connector on the dosing cabinet. In the first part of the instructions, the male connector was removed and replaced with a female connector in dosing cabinet. This section provides detail for removing the female connector on TWB and replacing with male connector.

The wire color scheme and lettering layout are the same as the dosing cabinet.

Follow the plug layout below to verify the installation is correct.

Note:
Optional Communications Wire: (Same as above)

On the 23 pin connector there is the possibility of a 5th wire (brown).
If this wire is present, move this wire to the correct location in the new connector.

Image1.6.1

TWB connector repair when completed should have the same look as Image below .

Image1.7.1

Tube Wire Bundle Assembly requiring Pigtail
(Only on systems with Heat Trace)

Early tube wire bundle assemblies did not include a three wire pair extension or "pig tail" to the 23 pin wiring.

Inside the TWB assembly the heat trace extends through the shrink boot and into the 23 pin plug direct. Removal of this wire and trimming to correct length
will be necessary to attach the three wire pair extension.

The following instructions are needed for successful installation.
To access to the heat trace in the tube wire bundle cutting the heat shrink boot off the TWB will be necessary. Do not use a razor blade using a razor blade to cut into the outer sheathing of the TWB will ruin its outer core. The preferred method is to use a pair of side cutters and a heat gun to warm up the glue and cut as it is heated.

Once the heat trace has been exposed follow these steps to connect the wire extension. Using wire cutters, cut heat tape down to 2 inch. See Image below.

Image1.8.1

Carefully cut off grey insulation. Be sure to leave mesh wire.

Image1.9.1

Carefully cut down and around the mesh wire leaving a few strands for ground wire. Twist the strands together.

Image1.10.1

Strip the next layer of insulation from the heat tape (polymer outer jacket),
revealing the self-regulating electrical heat trace. Cut straight down the middle, trim both wires and twist strands of mesh wire down to 1 1/2 inch. Also strip the ends of the two black wires.

Image1.11.1

Crimp the three connectors (from the pigtail) to the stripped wires. Crimp green wire to the mesh ground wire.

Image1.12.1

Use a heat gun to shrink the pink connectors on ends.

Image1.13.1

Cut a 3 3/4 inch piece of 1/2 inch heat shrink tubing enough to cover pink connectors and 1/4 inch of the pigtail wire insulation. Shrink to fit.

Note: Heat shrink tubing is not provided(dealer consumable).