PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENCLOSURE EMERGENCY STOP PUSH BUTTON ON CERTAIN C27 AND C32 GENERATOR SETS EQUIPPED WITH EMCP 4.2 Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENCLOSURE EMERGENCY STOP PUSH BUTTON ON CERTAIN C27 AND C32 GENERATOR SETS EQUIPPED WITH EMCP 4.2

Usage:

REBE9523-00

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27Mar2013

U-128

A-88

D-109

O-116

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE ENCLOSURE EMERGENCY STOP PUSH BUTTON ON CERTAIN C27 AND C32 GENERATOR SETS EQUIPPED WITH EMCP 4.2
1408 4490 7451		PI32159

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32159" 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 "PI32159" 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
30Sep2013	31Mar2014

PROBLEM

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The enclosure emergency stop push button needs to be reworked on certain C27 and C32 Generator Sets equipped with EMCP 4.2. The existing enclosure emergency stop push button will enable engine shut-down if engaged. However, releasing/re-setting this same emergency stop push button without having the control panel emergency stop push button engaged may allow the engine to start unexpectedly.

This problem does not affect open packages without enclosures, or the control box mounted emergency stop push button.

AFFECTED PRODUCT

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Model	Identification Number
C27	T4Z00203, 229, 233-234, 240, 243, 247
C32	JAZ00232, 372, 408, 412-414, 442 JSJ01907, 2144, 2156, 2167, 2170, 2173, 2179, 2181, 2190, 2198-2199, 2218, 2228, 2249, 2258, 2301, 2322, 2339, 2367, 2390, 2455, 2502, 2511, 2518, 2525, 2549, 2568, 2593, 2607, 2619, 2677, 2695, 2712, 2735, 2755, 2786, 2809, 2827, 2846, 2886, 2897, 2901, 2917, 2952, 2961, 2967, 2972, 2988, 2990, 2992, 2994, 2996-2999, 3002-3003, 3006-3007, 3010, 3016, 3019

PARTS NEEDED

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Qty	Part Number	Description
2	8T8729	PIN-CONNECTOR
2	1108714	END-WIRE
544	1304672	WIRE-BULK (CM)
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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Rework the enclosure emergency stop push button. Refer to the attached Rework Procedure.

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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 REWORKING THE ENCLOSURE EMERGENCY STOP PUSH BUTTON ON CERTAIN C27 AND C32 GENERATOR SETS EQUIPPED WITH EMCP 4.2

MODELS INVOLVED - C27 and C32

Dear Cat Product Owner:

The enclosure emergency stop push button needs to be reworked on the products listed. The existing enclosure emergency stop push button will enable engine shut-down if engaged. However, releasing/re-setting this same emergency stop push button without having the control panel emergency stop push button engaged may allow the engine to start unexpectedly. 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 27Mar2013 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 27Mar2013 Service Letter

Rework Procedure

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Isolate the generator set before commencing any work on the unit, open generator set breaker, activate the emergency stop push button on the control panel, and disconnect the battery cables. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

Only qualified repair personnel should service this equipment.

1) Using 130-4672 18 AWG wire make two wires 272 Cm long with a 110-8714 Wire End on one end and a 8T-8729 Connector Pin on the other end.

2) Remove top left side cover panel (A) from doghouse (If possible remove main roof panel as well). See Image 1.3.1.

Image1.3.1

3) Locate the 9X-1343 MA-C5 Connector. Disconnect engine interface harness from doghouse and remove the white plugs from pin locations 12 and 20. Plug the two wires (B) into locations 12 and 20 using the 8T-8729 Connector Pin ends. Reconnect the engine interface harness. See Image 1.4.1.

Image1.4.1

4) Open panel door to AC/DC box (C). See Image 1.5.1.

Image1.5.1

5) Locate the 398-9321 DC terminal strip 1 (D). Remove the jumper wire (E) from the AC/DC box that connects the BATT- Terminal to the ESTOP terminal. See Image 1.6.1.

Image1.6.1

6) Route the two wires through the hole (F) in the top of the AC/DC box as shown. Secure wires to prevent chaffing. Land wire from pin 20 in the BATT- terminal. Land wire from pin 12 in the ESTOP terminal (G). See Image 1.7.1.

Image1.7.1

7) Perform the following testing to ensure proper function of enclosure emergency stop push button:

1) Reconnect battery cables.

2) Release all emergency stop push buttons.

3) Place EMCP 4.2 in stop mode.

4) Clear all active emergency stop events.

5) Ensure the generator set is not running.

6) Activate the enclosure emergency stop push button.

7) Check the event log in the EMCP 4.2 for an active emergency stop condition.

8) Using the Cat ET communication adapter, verify the engine ECM sees the active shutdown condition (or engine ECM is not available).

9) Press the run button on the EMCP 4.2.

10) Place generator set in auto.

11) Release the enclosure emergency stop push button.

12) Clear the event in the EMCP 4.2. The red shutdown light on the EMCP 4.2 should go out.

13) Press the run key on the front of the EMCP 4.2.

14) Press the enclosure emergency stop push button. The engine should shutdown immediately, the red shutdown light on the EMCP 4.2 should flash, and the optional air shutoff should actuate.