REBE997000

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Service Letter
PRODUCT SUPPORT PROGRAM FOR INSTALLING A GROUND WIRE FOR THE AC
COMPRESSOR CLUTCH SOLENOID ON CERTAIN CT660 ON HIGHWAY TRUCKS
Media Number -REBE9970-00
Publication Date -01/08/2013
Date Updated -01/08/2013
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REBE9970-00
01Aug2013
U-345
Before/After
7000
PRODUCT SUPPORT PROGRAM FOR INSTALLING A GROUND
WIRE FOR THE AC COMPRESSOR CLUTCH SOLENOID ON
CERTAIN CT660 ON HIGHWAY TRUCKS
PS43978
NOTE:
This Program must 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
"PS43978" as the Part Number and "7755" as the Group Number. If
administered before failure, use "56" as the Warranty Claim
Description Code and "T" as the SIMS Description code. If
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administered after failure, use "96" as the Warranty Claim
Description Code, and "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.
TERMINATION DATE
31Aug2016
PROBLEM
There is not a ground wire to the AC relay coil. The deactivation of
the AC compressor clutch solenoid will not work properly. Thermal
switch and pressure switches will not work properly and on certain
CT660 On Highway Trucks failure of the AC compressor can occur.
AFFECTED PRODUCT
Model
CT660
Identification Number
TGA00001-00003, 5-6
TGT00103-00107
TJS00100
TKL00432-00435, 446-449, 451-458, 461-462, 464-587,
589, 598
TRK01236-01237, 1241-1249, 1256-1262, 1264-1361, 13631379, 1381-1425, 1428-1429, 1433-1454, 1456-1515, 15171520, 1522, 1524-1527, 1529-1553, 1555-1560
TSY00116, 119-130, 132-133, 135-142
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PARTS NEEDED
Part Number
Description
1
14AWG_WIRE
WIRE-WHITE 850mm
1
3962894
TERMINAL-CABLE
1
3962900
TERMINAL-CABLE
Qty
In order to allow equitable parts
availability to all participating dealers,
please limit your initial parts order to
not exceed 23% 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
Install a ground wire for AC relay inside of fuse/breaker panel of the
truck. Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age
whichever comes
first
0-250000 miles,
0-24 mo
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor
Hrs%
Parts %
Labor
Hrs%
Parts %
Labor
Hrs%
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job
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PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty
parts handling.
Rework Procedure
CT660 A/C COMPRESSOR GROUND REWORK
Issue: Missing ground wire to relay coil that activates/deactivates AC
compressor clutch solenoid on CT660 On Highway Trucks built without
APADS (Air Conditioning Protection and Diagnostic System).
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Image1.1.1
Tools/Parts Required:
1) Needle-Nose pliers (or equivalent extraction tool)
2) Socket tool
3) White 14AWG, 850mm wire (Terminated on both ends)
4) Fuse Panel 396-2900 Terminal
5) Splice Pack 396-2894 Terminal
6) Cutter/wire ties for IP harness routing/de-routing
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Rework:
1) Construct terminated wire by terminated one end with 396-2900
Terminal and the other end with 396-2894 Terminal.
2) Locate empty cavity in FB09, cavity M1-G1. Refer to Image1.3.1 and
Image1.3.2.
Image1.3.1
Image1.3.2
3) Remove the orange lock with a set of needle-nose pliers or similar
from the front.
4) Remove the fuse panel mounting bolts from the feet using a socket
tool.
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5) Cut away tie straps that may prevent the fuse panel from easily being
removed from inside the trim panels.
6) Carefully fold the fuse panel out so the missing wire location is
visible and can be worked on.
7) Insert a white 14awg wire into cavity M1-G1. Refer to Image1.4.1.
Image1.4.1
8) Insert the other end of the white wire to either Ground Splice Pack
453M or 456M (whichever one has a cavity available). Reference
Schematic, UNER1839.
9) Re-strap the IP harness as it was before rework (unless no tie straps
we cut).
10) Carefully reinstall fuse panel bolts to the feet of the fuse panel
using the socket wrench.
11) Re-insert the orange terminal lock to the front of the fuse panel.
12) Verify correct operation of the AC compressor system.
Copyright 1993 - 2013 Caterpillar Inc.
All Rights Reserved.
Fri Sep 6 13:09:50 CDT 2013
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