88263 Mercury WASHER, NEEDLE LOCATING

March 9, 2003
(Revised April 2003)
U-65
A-51
O-61
Safety PRODUCT IMPROVEMENT PROGRAM FOR RETROFITTINGEIS CIRCUIT BREAKER ON CERTAIN G3408C AND G3412C GAS ENGINES
1420 PI10223
This Program must be administered assoon as possible. When reporting the repair, use "PI10223" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI10223" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. This Revised Service Letter replacesthe March 9, 2003 Service Letter. Changes have been made to the AffectedProduct.PROBLEM
The Circuit Breaker needs to be changed to a fuseholder with a ceramic fuse on certain G3408C and G3412C Spark Ignited Engines.This will bring the terminal box into certified compliance.AFFECTED PRODUCT
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, 501,502PARTS NEEDED
Qty
Part Number Description
1 0365774 FUSE
1 1057543 BLOCK-FUSE USE ONLY CERAMIC A FUSE. (CaterpillarInc. Part 0365774) The use of non Caterpillar Inc. approved parts willvoid CSA approval and could be potentially dangerous.ACTION REQUIRED
See the attached Rework Procedure.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
100% 2.0 0 0 0 0
This is a 2.0-hour job. U.S. and Canadian Dealers Only - Eligibledealers may enter a Type 2 SIMS ReportPARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS 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 99999SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR RETROFITTINGEIS CIRCUIT BREAKERMODELS INVOLVED - CERTAIN G3408C AND G3412CGAS ENGINESDear Caterpillar Product Owner:The CB-3 Circuit Breaker, inside the enginemounted terminal box, needs to be changed to a fuse holder with a ceramicfuse on the products listed below. This will bring the terminal box intoCSA compliance for use in a gaseous environment. Until the circuit breakerhas been retrofitted with the fuse holder and fuse DO NOT use the circuitbreaker CB-3 to interrupt power to the terminal box. This could potentiallyresult in an explosion and fire hazard. You will not be charged for theservice performed.Contact your local Caterpillar dealer immediatelyto schedule this service. The dealer will advise you of the time requiredto complete this service. Please refer the dealer to their Service Letterdated March 9, 2003 when scheduling this service.We regret the inconvenience this may causeyou, but urge you to have this service performed for your added safetyand satisfaction.Caterpillar Inc.
Identification #(s)Attached to March 9, 2003 Service Letter
Rework Procedure
Locate and disconnect the source of customer?sswitched power which feeds into 1141143 Circuit Breaker in the engine mountedterminal box.
DO NOT disconnect power by switchingnonconforming CB-3 (1141143) to the off position as this could generatea spark.
Remove 1141143 Breaker As. from DIN rail.
Loosen the locking screws on the DIN rail lowerend block located just beneath the breaker.
Insert a 5-6 mm wide flat bladed screwdriver intothe open slot on the side of the breaker and pull outward to unlatch thebreaker from the DIN rail.
Unscrew the 2 screws securing the customer?s 24VDC power entering the right side of the breaker (P170-Red) and the internalharness connection (P270-Red) from the left side of the breaker.
Remove breaker and install a 1057543 Fuse blockwith 0365774 ceramic fuse. Check to insure the fuse block is locked ontothe DIN rail and retighten the DIN rail end block at the bottom of therail.
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 bothhold-down screws where the wires enter on both sides of the fuse block.
Close and secure Engine Mounted Terminal Box doorand reconnect the custom