PRODUCT SUPPORT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING COMPONENTS WITHIN THE ELECTRONIC THERMOSTAT ASSEMBLY ON CERTAIN C175 GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING COMPONENTS WITHIN THE ELECTRONIC THERMOSTAT ASSEMBLY ON CERTAIN C175 GENERATOR SETS

Usage:

REBE6930-03

10Nov2011
(Revised 26Mar2012)


U-497
A-407
D-437
O-441

 

Before/After

  
 Parts stock action needed 

PRODUCT SUPPORT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING COMPONENTS WITHIN THE ELECTRONIC THERMOSTAT ASSEMBLY ON CERTAIN C175 GENERATOR SETS

7750
PS43433
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 "PS43433" 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.

NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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.

 
NOTE:

This Revised Service Letter replaces the10Nov2011 (Revised 29Feb2012) Service Letter. Changes have been made to the Parts Needed.


TERMINATION DATE

30Nov2014

PROBLEM

The existing electronic thermostat motor on certain C175 Generator Sets could fail due to water entry that could consequently lead to corrosion of the motor. If the existing electronic thermostat motor fails, it can lead to improper cooling system temperature regulation and potential engine overheat. The thermostat could also fail to function if the drive pin slips out of the motor mount assembly shaft.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C175-16  WYB00100-00112, 114-118, 124-129, 131, 135-136, 138-454, 456-638
*******Group  2*******
C175-16  WYB00639-00668

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 1P4278 CLAMP-HOSE
1 2Y5829 NUT-HEX
2 3E4353 WASHER-HARD
1 5P9770 HOSE
1 6V4248 BOLT
1 8T4121 WASHER-HARD
1 8T4196 BOLT-HEX HEAD
1 9S9332 FITTING-ELBOW
1 9X8243 TUBE
1 1188706 SEAL-O-RING
1 1258797 CLIP
1 3122189 GASKET-MOTOR HSG
1 3122197 MOUNT AS-MOTOR (IF NEEDED)
1 3724980 BRACKET
1 3838593 MOTOR GP-ELEC -G (IF NEEDED)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*******Group 2*******
1 1P4278 CLAMP-HOSE
1 2Y5829 NUT-HEX
2 3E4353 WASHER-HARD
1 5P9770 HOSE
1 6V4248 BOLT
1 8T4196 BOLT-HEX HEAD
1 1258797 CLIP
1 3724980 BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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

****Parts Stock ****

Inspect all 278-7384 Motors and 365-9560 Motors in dealer parts stock.

Some dealer orders for the previous 278-7384 and 365-9560 Motors may have been fulfilled with the new 383-8593 Motor. A physical inspection of each part in dealer inventory will be required in order to determine if parts in stock are of the old design or the new design. The new motor design can be verified by opening the shipping box and verifying the label on the motor similar to Image1. Motors labeled with the new 383-8593 part number are the latest design motor and do not need to be removed from dealer stock.

- If the 278-7384 or 365-9560 Motor was fulfilled with the new 383-8593 Motor, return the motor to the original packaging, mark the correct part number on the box, also mark the package to indicate it has been inspected according to this program (PS4####) and then return the part to dealer parts stock.

- If the 278-7384 or 365-9560 Motor was not fulfilled with the new 383-8593 Motor, remove the motor from dealer parts stock.

 
Image1
 
****Affected Product****
Refer to Special Instruction, REHS7404, "Protecting the C175 Electronic Thermostat from Moisture Entry", for instructions on Disassembly and Assembly, Inspection and Component Replacement, as needed on the electronic thermostat.


Group 1 Rework Procedure

Step 1 - Follow the steps in the Special Instruction for removing the electronic thermostat motor in order to inspect for pin slippage and corrosion. If there are any signs of pin slippage, follow the steps to replace the Motor Mount Assembly

Step 2 - Follow the steps in the Special Instruction to install shrink wrap on the electronic thermostat harness going to the temperature control module.

Step 3 - Follow the steps in the Special Instruction to install a drain on the electronic thermostat motor housing cover.

Step 4 - Follow the steps in the Special Instruction to apply Loctite to the motor housing and cover joint.


Group 2 Rework Procedure

Step 1 - Follow the steps in the Special Instruction to install a drain on the electronic thermostat motor housing cover.

Step 2 - Follow the steps in the Special Instruction to apply Loctite to the motor housing and cover joint.

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

 
 
****Affected Product****
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-20000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 4.0-hour job for Group 1
An additional 4 hours is allowed if the motor mount assembly needs to be replaced.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-20000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.5-hour job for Group 2



PARTS DISPOSITION

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

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

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