PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER HEATER FUSE HOLDER ON CERTAIN C1.5 AND C2.2 POWERED GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER HEATER FUSE HOLDER ON CERTAIN C1.5 AND C2.2 POWERED GENERATOR SETS

Usage:

REBE5793-00

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15Jul2010

U-263

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER HEATER FUSE HOLDER ON CERTAIN C1.5 AND C2.2 POWERED GENERATOR SETS
1609 1383		PS51865

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51865" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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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.

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TERMINATION DATE

31Jul2011

PROBLEM

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The existing fuse holder used in the Jacket Water Heater (JWH) circuit can fail on certain C1.5 and C2.2 powered generator sets. If the existing fuse holder fails it will cause the JWH to be inoperable.

AFFECTED PRODUCT

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Model	Identification Number
C1.5	GBD00204-00206, 209-210, 213-219 NCA00360, 362, 381, 418, 421, 427
C2.2	GBE00169-00170, 220, 228-229, 231-234, 244-247, 271, 281-282, 287-289, 295-296, 326, 345-346, 362, 370, 376 NCB00385, 393, 479-481, 553, 573-574, 596

PARTS NEEDED

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Qty	Part Number	Description
1	0365774	FUSE
1	3483891	FUSE HOLDER AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Replace the existing fuse holder and fuse with the 348-3891 Fuse Holder and the 036-5774 Fuse.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-1000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 0.5-hour job

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PARTS DISPOSITION

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

Rework Procedure

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1. Isolate the generator set before commencing any work on the unit, open the generator set breaker, activate the emergency stop, disconnect the auxiliary power supply for the battery charger and heaters, and disconnect the battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

2. The current fuse holder assembly (1) is shown in Image 1.1.1.

Image1.1.1

3. Remove the Top Cover (1) and Cover (2) from the control panel by unscrewing eight M6 bolts (3), as illustrated in Image 1.2.1

Image1.2.1

4. Use an Allen Key to disconnect the EMCP3 controller from the wiring harness (1) as illustrated in Image 1.3.1.

Image1.3.1

5. Disconnect wires 132 & 134 (1) from the terminals on the JWH fuse holder F5, shown in Image 1.4.1. Remove the fuse holder from the panel body. Do not reuse.

Image1.4.1

6. A small key setting is required below the original one in the panel metalwork to fit the new fuse holder in the correct orientation. The location is detailed in Image 1.5.1. The key setting can be created in the panel metalwork by using a small grinding stone, similar to that displayed in Image 1.5.2, fitted in a rotary grinding tool. Particular attention should be made so that no damage occurs to the harness wiring during the grinding procedure.

Image1.5.1

Image1.5.2

7. Fit one 348-3891 Fuse Holder into the control panel (1) as illustrated in Image 1.6.1 and ensure that it is securely fitted. Reconnect wire 132 (2) to the rear terminal of the fuse holder and 134 (3) to the front terminal.

Image1.6.1

8. Unscrew the fuse holder cap and insert one 036-5774 15A Fuse. Screw the cap back into the fuse holder.

9. Reconnect the wiring harness to the EMCP3 controller, and replace the Top Cover and Cover removed in step 3.

10. Reconnect the auxilary supplies and check for correct operation of the JWH.

11. Run the generator set and check for correct operation.