PRODUCT SUPPORT PROGRAM FOR REWORKING THE WIRING FOR THE AUTO-STOP-RUN SWITCH ON CERTAIN C2.2, C3.3, AND C4.4 GENSET PANELS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE WIRING FOR THE AUTO-STOP-RUN SWITCH ON CERTAIN C2.2, C3.3, AND C4.4 GENSET PANELS

Usage:

REBE5809-00

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08Jul2010

U-249

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE WIRING FOR THE AUTO-STOP-RUN SWITCH ON CERTAIN C2.2, C3.3, AND C4.4 GENSET PANELS
1408		PS43114

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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 "PS43114" 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 administered after failure, use "96" as the Warranty Claim Description Code, and "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 shunt trip causes the main circuit breaker to open when the genset has the unit stopped in the auto position on certain C2.2, C3.3, and C4.4 Gensets. The existing wiring design has a DC supply to the shunt trip when in the auto position.

The protection relays (overload relay and under voltage timer) operate from the Genset AC supply. The protection relays are fail-safe units and default to the fault position when they are not powered. The power to the shunt trip is removed when the unit is in the OFF position and the breaker does not open.

AFFECTED PRODUCT

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Model	Identification Number
C2.2	GBE00123-00132, 143-148, 153-160, 162-168, 171-174, 181-183, 186, 206-208, 210-212, 214, 236, 238, 240, 243, 252-254, 269, 285-286, 290-293, 304, 312-314, 360
C4.4	GLE00301-00302, 700-722, 724-756, 770-771
C6.6	MRW00100-00102, 104-189

PARTS NEEDED

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Qty	Part Number	Description
24	8L8413	STRAP-CABLE
235	8T7875	WIRE
1	1364877	SPLICE-WIRE
7	2401405	TERMINAL-BLADE
1	3562774	SWITCH
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% 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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Install and rewire the new 356-2774 Auto-Stop-Run switch.

Refer to attached Rework Procedure.

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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%
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.5-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 genset before beginning any work on the unit: open the genset 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. Lock out generator before commencing any type of work.

2. Remove the knob from installed 2-pole Auto-Stop-Run switch.

3. Remove the applique from the installed 2-pole Auto-Stop-Run switch.

4. Remove mounting screws from installed 2-pole Auto-Stop-Run switch.

5. Move Auto-Stop-Run wires from 2-pole switch to new 3-pole switch, as shown in Image1.1.1.

Image1.1.1

6. Remove wire #7 from Overload Relay terminal 95. Insulate and tie back with 8L-8413 Cable Strap (Image 1.2.1 b).

7. Remove wire #7 from SDR/1 terminal 3. Insulate and tie back with 8L-8413 cable strap (Image1.2.1 c).

8. Use 45CM of 8T-7875 Wire and two 240-1405 Blade Terminals to add new wire #7B from Overload Relay terminal 95 to SDR/1 terminal 3 (Image 1.1.1 and Image 1.1.2 c).

Image1.2.1

9. Use 150CM of 8T-7875 Wire and two 240-1405 Blade Terminals to add new wire #7B from SDR/1 terminal 3 to new 3-pole Auto-Stop-Run switch terminal 14 (Image1.3.1 e).

10. Use 10CM of 8T-7875 Wire and two 240-1405 Blade Terminals to add wire jumper to connect new 3-pole Auto-Stop-Run switch terminal 1 to new 3-pole Auto-Stop-Run switch terminal 13 (Image1.3.1 f).

11. Use 30CM of 8T-7875 Wire, one 240-1405 Blade Terminal, and one 136-4877 Wire Splice to add Wire #24 from new 3-pole Auto-Stop-Run switch terminal 17 to splice in 24 wire near 4001-Series control board connector terminal.