PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE GLOW PLUG CIRCUIT ON CERTAIN XQ200 RENTAL GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE GLOW PLUG CIRCUIT ON CERTAIN XQ200 RENTAL GENERATOR SETS

Usage:

REBE9381-00

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22Feb2013

U-76

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE GLOW PLUG CIRCUIT ON CERTAIN XQ200 RENTAL GENERATOR SETS
1408 1412		PI32145

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32145" 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 "PI32145" 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
31Aug2013	28Feb2014

PROBLEM

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The engine glow plug circuit needs to be reworked on certain XQ200 Rental Generator Sets. The existing circuit can draw excessive current causing failure of a fuse.

AFFECTED PRODUCT

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Model	Identification Number
C7.1	MRP00100-00126, 129-130, 132, 135-142, 145-146, 148-156, 163

PARTS NEEDED

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Qty	Part Number	Description
3	2L8058	TERMINAL
1	2L8061	TERMINAL
1	2L8071	TERMINAL
8	6V5818	CONDUIT-FLEXIBLE
16	6V9023	TUBE
2	7X7729	WASHER-HARD
2	8T4137	BOLT-HEX HEAD
16	1193662	TUBE-HEAT SHRINK
12	1233202	STRAP-CABLE
4	1257875	TUBE-HEAT SHRINK
2	1283117	TERMINAL
3	1313201	BOOT
1	1364877	SPLICE-WIRE
1	2354451	BOLT-FLANGE HEAD
4	2462010	INSULATOR
1	2655679	RELAY
21	2865506	CONDUIT-FLEXIBLE
1	3639327	BRACKET AS.
244	WIRE_8AWG	RED POLYETHYLENE
10	WIRE_10AWG	GREEN WITH YELLOW POLYETHLENE
61	WIRE_14AWG	WHITE HEAT RESISTING PVC
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 28% 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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WARNING: Injury can occur to personnel if the procedure is done improperly.

Areas of improvement need to be addressed in order to prevent overload of the engine glow plug circuit. This includes adding a relay and harnesses to power the glow plug from the positive terminal of the electric starter.

Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework.

Proceed with the rework procedure for MRP00100-126. Units MRP00129-163 will require inspection for completed rework.

For MRP00129-163 only, inspect the XQ200 Rental Generator Set.

Inspect left rear of the engine block to determine if rework outlined in this procedure has been performed. Rework has been completed by the factory if there is a black bracket and a relay installed as indicated by Image 1. If the installation of these components are confirmed, DO NOT CONTINUE WITH THIS REWORK PROCEDURE.

WARNING: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tagout procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service.

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Image1

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

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 1.0-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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE GLOW PLUG CIRCUIT ON CERTAIN XQ200 RENTAL GENERATOR SETS

MODELS INVOLVED - XQ200

Dear Cat Product Owner:

The engine glow plug circuit needs to be reworked on certain XQ200 Rental Generator Sets. The existing circuit can draw excessive current causing failure of a fuse. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

Please refer the dealer to their Service Letter dated 22Feb2013 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 22Feb2013 Service Letter

Rework Procedure

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1. Harness Assembly

Make Harness (1). Image 1.1.1

Parts Required
Item# QTY
1 10 CM 10 AWG Wire Insulation Cross-Linked Polyethylene (Green with yellow stripe)
2 1 2L-8071 Terminal
2 4 CM 125-7875 Tube-Heat Shrink
3 1 128-3117 Terminal
4 2 246-2010 Insulator

Image1.1.1

Make Harness (2). Image 1.2.1

Parts Required
Item# QTY
1 152 CM 8 AWG Wire Insulation Cross-Linked Polyethylene (Red)
2 1 2L-8061 Ring Terminal
2 4 CM 119-3662 Tube-Heat Shrink
3 1 2L-8058 Ring Terminal
3 4 CM 119-3662 Tube-Heat Shrink
4 8 CM 6V-9023 Tube
5 130 CM 286-5506 Flexible Conduit
6 1 131-3201 Boot

Image1.2.1

Make Harness (3). Image 1.3.1

Parts Required
Item# QTY
1 92 CM 8 AWG Wire Insulation Cross-Linked Polyethylene (Red)
2 2 2L-8058 Ring Terminal
2 4x2CM 119-3662 Tube-Heat Shrink
3 8 CM 6V-9023 Tube
4 80 CM 286-5506 Flexible Conduit
5 2 131-3201 Boot

Image1.3.1

Make Harness (4). Image 1.4.1

Parts Required
Item# QTY
1 61 CM 14 AWG Wire Insulation Heat Resisting PVC (White)
2 1 136-4877 Terminal
3 1 128-3117 Terminal
4 2 246-2010 Insulator

Image1.4.1

2. Disconnect the current glow plug connection wire "58A" as indicated by Image 1.5.1, cut the ring terminal off and strip 7mm of insulation off of the wire. Image 1.5.2.

Image1.5.1

Image1.5.2

3. Install 265-5679 Relay to 363-9327 Bracket with 235-4451 Bolt.

Parts Required
QTY 1 265-5679 Relay
QTY 1 363-9327 Bracket
QTY 1 235-4451 Bolt

4. Relay Circuit Assembly
Refer to relay Image 1.6.1. Connect Harness (1) to relay terminal "85". Connect Harness (2) to relay terminal "30". Connect Harness (3) to terminal 87. Connect Harness (4) to terminal "86". Verify connections of the completed relay assembly. Image 1.6.2.

Image1.6.1

Image1.6.2

5. Install the relay assembly to the left side of the engine block using two 8T-4137 Bolts and two 7X-7729 Washers. Attach ring terminal end of Harness (1) between the washer and bolt head on the right side of the bracket. Image 1.7.1 Tighten to 55 +/-10 Nm.

Image1.7.1

6. Route Harness (3) from the relay up to the glow plug rail on the engine. Connect the ring terminal and tighten the bolt. Secure the harness to existing DC harness 380-4706 by installing cable ties every 12 inches along its length. Image 1.8.1

Parts Required
QTY 3 123-3202 Cable Tie

Image1.8.1

7. Locate stripped wire "58A" performed in Step 2. Image 1.9.1 Route Harness (4) along the DC harness and crimp the splice terminal to the bare wire. Use a heat gun to shrink the jacket of the splice to seal the connection. Image 1.9.2 Install 80 CM of 6V-5818 Flexible Split Conduit onto this wire from the DC harness to the relay connection. Secure the harness to the DC harness with cable ties every 12 inches.

Parts Required
QTY 3 123-3202 Cable Tie

Image1.9.1

8. Route Harness (2) along DC wire harness under the oil pan of the engine. Remove the nut and washer from the positive (B+) terminal of the electric starter. Connect the ring terminal from the harness to the terminal. Secure the harness to the DC harness with cable ties every 12 inches. Image 1.10.1.

Parts Required
QTY 4 123-3202 Cable Tie

9. Verify all connections have been made properly and secure any additional points along the harness with cable ties if necessary.