PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE ECM PANEL ON CERTAIN C175-16 PETROLEUM GENERATOR SET ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE ECM PANEL ON CERTAIN C175-16 PETROLEUM GENERATOR SET ENGINES

Usage:

REBE8534-00

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13Aug2012

U-424

D-364

O-393

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE ECM PANEL ON CERTAIN C175-16 PETROLEUM GENERATOR SET ENGINES
7426 1408		PI32080

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32080" 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 "PI32080" 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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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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COMPLETION DATE	TERMINATION DATE
28Feb2013	31Aug2013

PROBLEM

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The ECMs on certain C175-16 Petroleum Generator Set Engines can experience input signal interference causing irregular engine rpm. The throttle and timing input signals can be corrupted due to electrical interference when wired through the diode block. If the existing wiring circuits are not changed, poor engine stability will result.

AFFECTED PRODUCT

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Model	Identification Number
C175-16	P6L00100-00103, 105-160

PARTS NEEDED

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Qty	Part Number	Description
22	7G7917	PLUG-SEALING
20	7K1181	STRAP-CABLE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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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 4.0-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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE ECM PANEL ON CERTAIN C175-16 PETROLEUM GENERATOR SET ENGINES

MODELS INVOLVED - C175-16

Dear Caterpillar Product Owner:

The ECM panel needs to be rewired on the products listed below. The engine can experience poor engine performance if the secondary ECM takes control of the engine. 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 13Aug2012 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 13Aug2012 Service Letter

Rework Procedure

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1) Cut wire ties securing wiring harness inside ECM panel.

THROTTLE

2) Remove wires G807-E171 (pin 31, blue 18 ga) from left diode block connector (E-C20), G807-E186 (pin 31, blue 18 ga) from right diode block connector (E-C19), and G807-E100 (pin 40, blue 18 ga) from center diode block connector (E-C21).

Image1.1.1

3) Reroute G807-E100 from above diode block to below and splice with G807-E171 and G807-E186 using solder and shrink tubing.

Image1.2.1

NOTE: Twisted pair wires should maintain one twist per 25 mm of length.

PRIMARY SPEED SENSOR

The primary speed sensor wiring is a twisted pair.

4) Remove wires E908-E35 (pin 44, brown 18 ga) and E909-E132 (pin 43, white 18 ga) from left diode block connector (E-C20), E908-E152 (pin 44, brown 18 ga) and E909-E153 (pin 43, white 18 ga) from right diode block connector (E-C19), and E908-E133 (pin 27, brown 18 ga) and E909-E25 (pin 28, white 18 ga) from center diode block connector (E-C21).

Image1.4.1

5) Reroute twisted pair E908-E133/E909-E25 from above diode block to below and splice with twisted pair E908-E152/E909-E153 and twisted pair E908-E35/E909-E132, respectively, using solder and shrink tubing.

Image1.5.1

SECONDARY SPEED SENSOR

The secondary speed sensor wiring is a twisted pair.

6) Remove wires E963-E44 (pin 27, black 18 ga) and E964-E41 (pin 64, white 18 ga) from left diode block connector (E-C20), E963-E237 (pin 27, black 18 ga) and E964-E253 (pin 64, white 18 ga) from right diode block connector (E-C19), and E963-E47 (pin 44, black 18 ga) and E964-E46 (pin 7, white 18 ga) from center diode block connector (E-C21).

Image1.6.1

7) Reroute twisted pair E963-47/E964-E46 from above diode block to below and splice with twisted pair E963-E237/E964-E253 and twisted pair E963-E44/E964-E41, respectively, using solder and shrink tubing.

Image1.7.1

TERTIARY SPEED SENSOR

The tertiary speed sensor wiring is a twisted pair.

8) Remove wires E965-E131 (pin 7, blue 18 ga) and E966-E26 (pin 32, yellow 18 ga) from left diode block connector (E-C20), E965-E196 (pin 7, blue 18 ga) and E966-E198 (pin 32, yellow 18 ga) from right diode block connector (E-C19), and E965-E36 (pin 64, blue 18 ga) and E966-E130 (pin 39, yellow 18 ga) from center diode block connector (E-C21).

Image1.8.1

9) Reroute twisted pair E965-36/E966-E130 from above diode block to below and splice with twisted pair E965-E196/E966-E198 and twisted pair E965-E131/E966-E26, respectively, using solder and shrink tubing.

Image1.9.1

LEAK DETECTION POWER SUPPLY

10) Verify and disconnect wire P907-E208 (pin 4, green 18 ga) from primary ECM J1 (E-C1).

11) Trace wire 118-E294 (pin 59, red 16 ga ) of primary power connector (E-C39) to the splices with 118-E279, 118-E24, 118-E295, and 118-E357.

Image1.10.1

12) Splice 118-E294 with P907-E208 using solder and shrink tube.

Image1.11.1

13) Use 7G-7917 Sealing Plugs to plug holes where wires were removed from connections.

14) Finish by securing all harnesses with 7K-1181 Cables Straps.