PRODUCT SUPPORT PROGRAM FOR INSTALLING THE WIRING GP (1G1U) ON CERTAIN 3512C HD AND 3516E GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING THE WIRING GP (1G1U) ON CERTAIN 3512C HD AND 3516E GENERATOR SETS

Usage:

TEBE9100-00

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19May2019

U-292

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSTALLING THE WIRING GP (1G1U) ON CERTAIN 3512C HD AND 3516E GENERATOR SETS
1408 4460		PS46268

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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 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 "PS46268" 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.

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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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TERMINATION DATE

31May2021

PROBLEM

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The wiring group (1G1U) was not installed at the factory on certain 3512C HD and 3516E Generator Sets. If the wiring group (1G1U) is not installed, it will not allow the generator sets to operate in a parallel mode as intended.

AFFECTED PRODUCT

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Model	Identification Number
3512C HD	LYP00159-00164, 174-178
3516E	JD700155-00157, 164, 166, 170-171, 173-174, 177, 179-180, 184, 186, 197-201, 204-205, 208-209, 213, 215, 219, 225-228, 230, 232, 240-241

PARTS NEEDED

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Qty	Part Number	Description
1	5496900	WIRING GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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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 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 unintended operation the unexpected movement, 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.

Action Required

Refer to the attached Rework Procedure for steps to install the missing wiring group.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-2500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	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.

Rework Procedure

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NOTE: Ensure that health and safety requirements are adhered to at all times.

1. Install the terminal block assembly inside the control panel, using the supplied hardware.? Ensure the terminal block assembly is mounted to the two most inboard weld bosses on the bottom of the control panel box, with the relays closer to the back of the panel (?A1? and ?A2? terminals of the relay bases on the left side).?See Image1.1.1

Image1.1.1

2. Place the DO 10/DO 11 film next to the relays on the floor of the control box. The DO 10 relay is closest to the AI(4)+ terminal. See Image1.2.1.

Image1.2.1

3. Install the non-socketed wire ends of the 549-6901 harness into the new terminal block assembly. Reference table and image in Image1.3.1.

Image1.3.1

4. Land the 229-T14 (gray) wire to an existing Batt- terminal on the main DIN rail.

5. Route and secure the harness along the existing harnesses, and inside the Panduit (when necessary), to the EMCP. See Image1.5.1.

Image1.5.1

6. Securely insert the following socketed wire ends of the 549-6901 harness into the 70-pin connector attached to the EMCP (P-C1). Reference table and image in Image1.6.1.

Image1.6.1

7. Securely insert the following socketed wire ends of the 549-6901 harness into the 120-pin connector attached to the EMCP (LA-C6). Reference table and image in Image1.7.1.