PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LEAK DETECTION DEVICE ON CERTAIN 3516C HD AND C175-16 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LEAK DETECTION DEVICE ON CERTAIN 3516C HD AND C175-16 GENERATOR SETS

Usage:

TEBE6945-01

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13Nov2017

(Revised 13Mar2018)

U-625

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LEAK DETECTION DEVICE ON CERTAIN 3516C HD AND C175-16 GENERATOR SETS
1273 1274 1280		PI32816

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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 as soon as possible. When reporting the repair, use "PI32816" 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 "PI32816" 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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NOTE:	This Revised Service Letter replaces the 13Nov2017 Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31May2018	30Nov2018

PROBLEM

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The currently installed secondary containment leak detection float switch may malfunction on certain 3516C HD and C175-16 Generator Sets.

AFFECTED PRODUCT

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Model	Identification Number
3516C HD	SEK01145, 1150-1151, 1166, 1174-1177, 1203, 1205, 1208, 1212
C175-16	WYB01825-01826, 1840-1841, 1846-1853, 1857-1860, 1862-1863, 1871, 1876-1877, 1885, 1888-1890, 1914-1920, 1925-1927, 1929, 1931, 1936-1940

PARTS NEEDED

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Qty	Part Number	Description
1	SENSOR	LEAK DETECTION DEVICE HS100-ND
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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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 2.0-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 REPLACING THE LEAK DETECTION DEVICE

MODELS INVOLVED - CERTAIN 3516C HD AND C175-16 GENERATOR SETS

Dear Cat Product Owner:

The leak detection float switch needs to be replaced on the products listed below. The existing leak detection float switch can malfunction. 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 13Nov2017 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 13Nov2017 Service Letter

Rework Procedure

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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 not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and 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.

REPAIR ACTION REQUIRED

Replace the current secondary containment leak detection float switch with a conductive polymer leak detection device (HS100-ND).

NOTE: The leak detection device HS100-ND should have already been shipped to the affected sites. If a dealer does not have the leak detection device, or if there are questions regarding the leak detection device, have the Dealer Technical Communicator (TC) submit a request regarding the leak detection device to CPI number 397713 through CPI Feedback within the Service Information Management System (SIMSi).

FUEL TANK LEAK INSPECTION

1. Remove the secondary basin vent cap from the secondary tank.

2. Use flashlight for visual inspection of inside of the secondary tank. Look for any evidence of fuel.

3. If fuel is present have the Dealer Technical Communicator (TC) submit a request through CPI Feedback within the Service Information Management System (SIMSi).
Reference CPI number 397713 and document the following:
SITE LOCATION
TANK SERIAL NUMBER
PACKAGE SERIAL NUMBER
ESO

LEAK DETECTION DEVICE INSTALLATION

4. Turn off Pneumercator console.

5. Remove existing Pneumercator leak sensor & wire if previously installed. If not, remove pipe plug from spare port / opening.

6. Install new leak sensor and run new leak sensor wire into a water-tight box.

7. Install and plug in the connectors.

8. Disconnect one or both sensor wires at the console and measure the DC resistance across the sensor wires. Reading should be nominally 50k ohms, +/- 15k ohms.

9. Reconnect sensor wires at the console and turn on.

10.Connect laptop or reprogram from the display panel (reference pg 13 of the Pneumercator Operation and Maintenance Manual Model TMS2000 and TMS3000). Reprogram leak sensor input to provided HS100ND leak detector settings (reference pg 55 - 56 of the Pneumercator Operation and Maintenance Manual Model TMS2000 and TMS3000) and reprogram relay 1 to activate on leak detection (reference pg 47 - 48 of the Pneumercator Operation and Maintenance Manual Model TMS2000 and TMS3000). Leak Trigger to be set at 1 1-0-0 and Set Point #1 Trigger to be set at 0-0-0.

11.Disconnect one wire at the field connection closest to the sensor. Confirm the console alarms. Reconnect wire.

12.Facebook ? At the BMS, to rename indicator name from HIGH FUEL to LEAK.

13.Clean up and leave no foreign material in the area.