PRODUCT SUPPORT PROGRAM FOR RELOCATING THE AIR INLET TEMPERATURE SENSOR ON CERTAIN C175 GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR RELOCATING THE AIR INLET TEMPERATURE SENSOR ON CERTAIN C175 GENERATOR SETS

Usage:

REBE7741-00

04Jan2012


U-6
A-5
D-7
O-5

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR RELOCATING THE AIR INLET TEMPERATURE SENSOR ON CERTAIN C175 GENERATOR SETS

1921 1439 1928
PS52157
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 "PS52157" 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.

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

31Jan2014

PROBLEM

The air inlet sensor at its current location may read the air inlet temperature inaccurately on certain C175 Genset installations. The high air inlet temperature reading can lead to an engine derate due to an E368(2) event code in the ECM or a 172-16 Engine Air Inlet Temperature: High - moderate severity (2) on the EMCP Panel.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C175-16  WYB00302-00454, 456-574, 576-626
*******Group  2*******
C175-16  WYB00100-00112, 114-118, 124-129, 131, 135-136, 138-301

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
4 7X7729 WASHER
2 8T4133 NUT
2 8T4195 BOLT-HEX HEAD
4 2287088 SEAL-O-RING-ORFS
4 2385079 SEAL-O-RING-STOR
1 2416157 PLUG-HD STOR
1 3739667 SUPPORT AS
1 3774548 HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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*******
4 2P1279 LOCKNUT-BULKHEAD
9 2W4379 PLATE
4 6V7728 BOLT-HEX HEAD
4 7X7729 WASHER
1 8T0640 BOLT
2 8T4133 NUT
2 8T4195 BOLT-HEX HEAD
5 9X8267 WASHER
9 1388240 CLAMP-TUBE
4 1505030 INDICATOR-AIR
12 2287088 SEAL-O-RING-ORFS
7 2287100 SEAL-O-RING-STOR
4 2385079 SEAL-O-RING-STOR
4 2416157 PLUG-HD STOR
1 2961291 SUPPORT AS
4 3048007 TEE-ORFS
4 3295462 CONNECTOR-STOR
1 3369847 TUBE AS
1 3369850 TUBE AS
1 3369851 TUBE AS
1 3369852 TUBE AS
1 3739667 SUPPORT AS
1 3774548 HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 3.0-hour job for Group 1

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-2000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 6.0-hour job for Group 2



PARTS DISPOSITION

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


Rework Procedure


Group Number 1  
 
1. Remove the four air filter restriction indicators and store for reuse.

2. Loosen four 227-0128 Nuts on the tube assemblies to free from the connectors.

3. Remove two M10 nuts and remove the support assembly. Store the M10 for reuse.

Refer to Image1.1.1 and Image1.1.2.
Image1.1.1
Image1.1.2
 
4. Remove the 238-0012 Sensor from the air cleaner and store for reuse.

5. Install the 241-6157 Plug in the port.

Refer to Image1.2.1.
Image1.2.1
 
6. Remove the 329-5462 Connector and the 2P-1279 Locknut from the bracket and store for reuse.

7. Place the connector and locknut in the new 373-9667 Support Assembly. Tighten the locknuts to 10 ft-lbs.

8. Place the 238-0012 Sensor in threaded hole of the support assembly and tighten to 15 ft-lbs.

Refer to Image1.3.1 and Image1.3.2.
Image1.3.1
Image1.3.2
 
9. Secure the support assembly to the 296-1291 Plate and secure with M10 bolts, washers, and nuts. Tighten the M10 bolts to 40 ft-lbs.

10. Use four new 228-7088 O-rings and place four 227-0128 Nuts from the tube assemblies on the connectors and tighten to 10 ft-lbs.

11. Assemble the four 150-5030 Air Indicators that were previously removed using four new 238-5079 O-rings. Refer to Image1.4.1 and Refer1.4.2.
Image1.4.1
Image1.4.2
 
12. Replace temperature sensor by replacing the old wiring with the new 377-4548 Wiring Group. Attach the new wiring to the pressure sensors locations and ensure that the harness temperature sensor lead is connected to the temperature sensor at its new location as shown in the oval. Refer to Image1.5.1 and Image 1.5.2.
Image1.5.1
Image1.5.2
 
 
Group Number 2  
 
1. Update the old hose design 322-5760 Air Filter Change Indicator Gp to the new steel tubing design 336-9854 Air Filter Change Indicator Gp. Refer to Engine News, "A New Air Filter Change Indicator Group Is Used on C175-16 Generator Set". Refer to Image 2.1.1.

NOTE. The 296-1291 Support Assembly has to be replaced to accommodate the additional bolt holes.
Image2.1.1
 
2. Replace temp sensor by replacing the old wiring with new 377-4548 wiring group. Attach new wiring to the pressure sensors locations and ensure that the harness temperature sensor lead is connected to the temperature sensor at its new location as shown in the oval. Refer to Image2.2.1 and Image2.2.2.
Image2.2.1
Image2.2.2
 
 

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