PRODUCT IMPROVEMENT PROGRAM FOR PROVIDING ELECTRICAL INTERLOCK FOR DUAL AIR SHUTOFF CONFIGURATION ON CERTAIN PETROLEUM C32 GENERATOR SETS ORDERED FROM THE ELECTRIC POWER PRICELIST Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR PROVIDING ELECTRICAL INTERLOCK FOR DUAL AIR SHUTOFF CONFIGURATION ON CERTAIN PETROLEUM C32 GENERATOR SETS ORDERED FROM THE ELECTRIC POWER PRICELIST

Usage:

REBE6305-00

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28Jul2010

U-275

O-238

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR PROVIDING ELECTRICAL INTERLOCK FOR DUAL AIR SHUTOFF CONFIGURATION ON CERTAIN PETROLEUM C32 GENERATOR SETS ORDERED FROM THE ELECTRIC POWER PRICELIST
1078 1408		PI10811

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10811" 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 "PI10811" 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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PROBLEM

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The 279-6507 Basic Shutoff Group on certain C32 Petroleum Gensets ordered from the Electric Power Price list ships with two air shutoffs. There is currently no interlock ensuring that both air shutoffs operate together. Operating the engine with one air shutoff closed and the other air shutoff open will cause catastrophic engine failure and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
C32	SXC00694, 735, 741, 1808, 2315, 2333, 2760, 2787, 4582, 4898, 5021, 5064, 5067, 5072, 5141

PARTS NEEDED

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Qty	Part Number	Description
4	2A0762	BOLT
1200	5P5623	WIRE-ELECTRICAL
1	5P6460	GROMMET
2	6V8541	PLUG-BUTTON
4	7E7731	MOUNT
2	8T0337	SCREW-MACHINE
5	8T8729	PIN-CONNECTOR
9	8T8730	SOCKET-CONNECTOR
4	9S8750	NUT-FULL
1	0975921	RAIL-MTG
8	1146658	WASHER-HARD
1	1474552	BOX AS
1	1552274	PLUG KIT-CONN
2	2110640	SPRING-RELAY
2	2236470	RELAY
2	2521731	MODULE-DIODE
2	2521732	BASE-RELAY
2	2606684	NUT
1	2762332	SWITCH AS-TOGGLE
2	3149101	BRACKET-END
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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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Reconfigure the dual air shutoff electrical circuit, to incorporate an electrical interlock circuit, which ensures that when one air shutoff solenoid closes the other air shutoff also closes.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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 2.0-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.

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 PROVIDING ELECTRICAL INTERLOCK FOR DUAL AIR SHUTOFF CONFIGURATION ON CERTAIN PETROLEUM C32 GENERATOR SETS ORDERED FROM THE ELECTRIC POWER PRICE LIST

MODELS INVOLVED - C32 PETROLEUM GENSETS

Dear Caterpillar Product Owner:

The dual air shutoff circuit on certain C32 petroleum generator sets, that were ordered from the Electric Power price list, need to be reworked on the products listed below. Operating the engine with one air shutoff closed and the other air shutoff open will cause catastrophic engine failure and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. This situation will occur if one of the air shutoffs fails to operate properly, or if someone manually activates one of the air shutoffs using the red "stop handle" on the air shutoff.

The rework will implement an electrical interlock circuit, which will ensure that both air shutoffs will operate whenever either is activated. Additionally, by wiring an input into the EMCP, the unit will shutdown and will not restart if either or both of the air shutoffs are closed.

You will not be charged for the 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 28Jul2010 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 28Jul2010 Service Letter

Rework Procedure

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Abbreviations

ASLR - Air Shutoff Left Relay
ASOS ? Air Shutoff Switch
ASSL ? Air Shutoff Solenoid Left
ASSR ? Air Shutoff Solenoid Right
ASR ? Air Shutoff Relay
ASRR - Air Shutoff Right Relay
ASRS - Air Shutoff Reset Switch
ASRT ? Air Shutoff Relay Timer
LSL ? Limit Switch Left
LSR ? Limit Switch Right

Mounting Box Modification

1. Drill a 3.5mm hole and a 12.5mm hole in the top cover to allow for switch mounting.

Image1.1.1

2. Enlarge one hole as indicated in Image 1.2.1 to a 27mm hole to allow for installation of grommet and for wires to exit.

Image1.2.1

3. Drill 2 - 5.5mm holes in the bottom to allow for DIN rail mounting in box.

Image1.3.1

4. Drill 4 - 7.9mm holes in the frame rail to mount the enclosure.

Image1.4.1

Image1.4.2

Mounting Box Assembly

Image1.5.1

Image1.5.2

Image1.5.3

Image1.5.4

5. Cut the 097-5921 Rail to a length of 124mm.

6. Assemble the cut section of 097-5921 Rail to the inside of the bottom of the 147-4552 Box Assembly with the 8T-0337 Screws and 260-6684 Nuts. The nuts should be on the outside of the box.

7. Snap the two 252-1732 Bases and two 314-9101 Brackets onto the installed 097-5921 rail as shown in Image1.5.1, Image1.5.2, and Image1.5.3.

8. Install one 223-6470 Relay, one 252-1731 Diode Module into each of the two 252-1732 Bases.

9. Retain each of the two 223-6470 Relays with a 211-0640 Spring.

10. Install the 276-2332 Switch into the cover of the 147-4552 Box.

11. Install the 5P6460 Grommet into the 27mm hole on the side of the 147-4552 Box.

12. Install a 6V-8541 Plug into each of the 2 remaining holes on the side of the 147-4552 Box.

13. Assemble a 7E-7731 Mount with a 114-6658 Washer and a 9S-8750 Nut in each of the four holes on the 147-4552 Box.

Image1.6.1

Circuit Changes

NOTE: Wire circuits referred to as 5P-5623 Black Wire use 5P-5623 Black Wire cut to the appropriate length as needed.

14. Remove all sources of power to the genset following local lock-out tag-out procedures.

15. Locate the 282-4361 Air Shutoff Group for the left side of the engine.

16. Remove the four screws and the cover from the terminal box on the 143-3878 Valve Assembly.

17. Disconnect the blue wire from the terminal block position 3. This wire will not be reused. Insulate the wire to prevent it from shorting on other components.

18. Disconnect the yellow wire (N.O. contact) from terminal block position 0 and reconnect to terminal block position 3.

19. Disconnect the brown wire from position 0 of the connector side of the terminal block and reconnect on position 0 of the solenoid side of the terminal block.

20. Swap the COM and brown wires in positions 1 and 2 of the terminal block so the brown wire is connected to position 1 and the COM wire is connected to position 2.

21. Disconnect the red wire from position 1 of the terminal block and reconnect to position 0. This red wire should come from the 2 pin, 3E-3364 DT connector.

22. Disconnect the black wire from position 2 of the terminal block and reconnect to position 1. This black wire should come from the 2 pin, 3E-3364 DT connector.

23. Connect a new 5P-5623 Black Wire labeled "ASLR-LSL" to terminal block position 3 of the left side 282-4361 Air Shutoff Group. Route outside the terminal box through the grommet on the 143-3878 Valve Assembly. Route to the new box assembly, which will be mounted on the frame rail as shown in the Base Modification instructions. Enter the box assembly through the 5P-6460 Grommet on the side. Connect the other end of the new 5P-5623 Black Wire labeled "ASLR-LSL" to the battery positive side of the coil for the 223-6470 Relay Assembly ASLR by connecting it to the 252-1732 Relay Base terminal A1.

24. Attach a new 5P-5623 Black Wire labeled "BATT +" to terminal block position 2. Route this wire outside the terminal box through the grommet on the 143-3878 Valve Assembly and connect to Splice S2.

Image1.7.1

25. Remove the G971-G2 RD-16 wire from position 1 of the 2-pin, 3E-3361 DT (G-C1) connector that connects to the Shutoff GP ? Air (282-4361). Add a new black wire labeled "SOGL-ASLR" into position 1 of connector G-C1. Route to the new box assembly and enter through the grommet. Connect to 223-6470 Relay Assembly ASLR terminal 12 (N.C.).

26. Replace the cover and 4 screws on the 282-4361 Air Shutoff Group.

27. Steps 15 thru 25 need to be repeated for the Right Side 282-4361 Air Shutoff Group using the 2nd 223-6470 Relay Assembly ASRR contained within the added box assembly.

28. Connect a new 5P-5623 Black Wire labeled "BATT +" between Splice S1 and S2. Splice S1 is located on the circuit 119-E11 RD-16 that connects the 148-0757 ASR Relay and 6T-3642 ASOS Breaker together.

Image1.8.1

29. Connect a new 5P-5623 Black Wire labeled "BATT +" from the splice S2 to the Position 1 of the ASRS 6-pin, 155-2274 DT connector located in the 147-4552 Box Assembly.

30. Connect a new 5P-5623 Black Wire labeled "BATT-" to splice S3. Splice S3 is located on the circuit 200-E8 BK-16 of position 8 on the 8-pin, 3E-3385 DT connector E-C1. Complete the rest of the BATT- circuit by routing circuits shown at splices S4 and S5. These wires will be labeled "BATT-". Include relay assembly terminals 31 and A2 of the 223-6470 ASLR Relay and the 223-6470 ASRR Relay. Also, include position 6 of the ASRS 6-pin, 155-2274 DT Connector located in the 147-4552 Box Assembly.

31. Remove and insulate the red wire from position 7 of the 8-pin, 155-2264 DT Connector A-C38 that connects to the 282-4358 ASOS Harness. Replace this with new black wire (5P-5623) labeled "ASR" that connects to terminals 11 and 21 of both 223-6470 ASLR and 223-6470 ASRR Relay Assemblies. Label these wires "ASO SIGNAL". See splices labeled S8 and S9 in the schematic below.

Image1.9.1

32. Complete the ASLR and ASRR N.O. control circuits by connecting new 5P-5623 Black Wires between position 24 of the 252-1732 ASLR and the 252-1732 ASRR Relay Assemblies (see splice S7) and position 2 of the ASRS 6-pin, 155-2274 DT Connector located in the 147-4552 Box Assembly.

33. Connect a new 5P-5623 Black Wire to terminal 34 of both relay assemblies and splice them together (S6). Connect a 5P-5623 Black Jumper Wire between splice S6 and position 5 of the ASRS 6-pin, 155-2274 DT connector located in the 147-4552 Box Assembly. Run a 5P-5623 Black Wire labeled "DIGITAL AIR SHUTOFF" from this splice (S6) to the doghouse enclosure 40-pin, 9X-1343 Connector. Populate an empty pin/socket of the 40-pin 9X-1343 Connector and continue it to route a black wire to the AC/DC panel. This will connect to EMCP digital input number 6 within the AC/DC panel and label this wire "DIGITAL AIR SHUTOFF".

34. Assemble the Box Assembly to the frame rail using the four 2A-0762 Bolts and four 114-6658 Washers to the frame rail in the location modified in the Base Modification section.

35. Program digital input number 6 as a shutdown event within the EMCP. Refer to the EMCP 3 Systems Operation Manual (media # RENR7902)