Usage:
08Dec2014 |
Before/After | PRODUCT SUPPORT PROGRAM FOR REWORKING THE SHORE POWER WIRING AND JACKET WATER HEATER WIRING ON CERTAIN C9 GENERATOR SETS |
|
1383 7405 7002 | PS44594 |
NOTE: | Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar. |
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 "PS44594" 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: | 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 |
31Dec2016 |
PROBLEM
The existing shore power wiring and jacket water heater wiring may be wired incorrectly on certain C9 Generator Sets. This may inhibit functionality of the jacket water heaters. |
AFFECTED PRODUCT
Model | Identification Number |
C9 | NGP00102, 111 |
PARTS NEEDED
Qty |
Part Number | Description |
5 | 1993062 | FILM-LABEL |
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
Refer to the attached Rework Procedure. |
SERVICE CLAIM ALLOWANCES
0-24 mo |
NOTE: This is a 1.5-hour job | ||||||
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
Important Safety Information Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly. Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use. The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used. WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine. |
Tools required ? Flat head screwdriver, Phillips head screwdriver, Heat gun Parts required ? 199-3062 ? Film-Label (heat shrink) |
1)Locate and open panel to access wiring for the shore power and jacket water heater control relay. |
Image1.3.1 |
2)Locate the CR relay and DC Battery terminal inside the panel. |
Image1.4.1 |
3)Remove CR-A2/208-RC2/BTRY- wire from terminal A2 of the CR Relay and the other end of this wire from BTRY- terminal. Label the wire to CR-A1/108-RC2/BTRY+ on both ends. Terminate this wire it to A1 terminal of the CR relay (see A) and the other end of the wire to the BTRY+ terminal (see B). |
Image1.5.1 |
Image1.5.2 |
4)Remove CR-A1/A309-RC1/FL EN RLY wire from A1 terminal of the CR relay. Label the wire to CR-A2/A309-RC1/FL EN RLY and terminate it to A2 terminal of the CR Relay (see C). |
Image1.6.1 |
Image1.6.2 |
5)Remove CR12/A338/EN261 wire from terminal 12 of the CR Relay. Label the wire from CR-12 to CR-14 and terminate the wire to terminal 14 of the CR relay (see D). |
Image1.7.1 |
6)Locate the HCR relay. Verify the Brown and Blue AC power wires for the JWH are landed at terminals 12 and 22 (see E). If the wiring is not landed at these terminals they may have been landed at the Cust L1/L2 connections and need to be corrected. |
Image1.8.1 |
Additional rework required on EMCP 4.3/4.4 equipped units |
7)Remove the bridge/Jumper off of terminal 11of RLY15. Swap RLY 15 and RLY 16 positions (RLY15 down and RLY16 up). Clip bridge/jumper and reinstall (see F). |
Image1.10.1 |
Image1.10.2 |
8)Remove wire A309-RC1 from terminal 12 and terminate it to terminal 14 of the RLY15 relay. Add a label 14 on this wire (see G). |
Image1.11.1 |
9)Run a wire from terminal 11 of the RLY15 relay to BTRY-. Label this wire ?RLY15-11/208-CJ1/BTRY-? (see H). |
Image1.12.1 |
Image1.12.2 |