PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE EMCPII PANEL ON CERTAIN G3508, G3512, AND G3516 GAS ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE EMCPII PANEL ON CERTAIN G3508, G3512, AND G3516 GAS ENGINES

Usage:

SEBE8247-01

January 6, 2003
(Revised January 2003)
U-7
A-4
D-3
O-5

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE EMCPII PANEL ON CERTAIN G3508, G3512, AND G3516 GAS ENGINES
1058		PI30339

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30339" 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 "PI30339" as the Part Number, "7751" as the Group Number, "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.

NOTE: This Revised Service Letter replaces the January 6, 2003 Service Letter. Changes have been made to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
July 31, 2003	January 31, 2004

PROBLEM

The EMCPII panel on certain G3508, G3512, and G3516 gas engines needs to be rewired. The predetonation shut down interconnect wiring to the EMCPII panel may be miswired and the unit may not shut down if predonation is determined by the EIS module.

AFFECTED PRODUCT

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Model	Identification Number
G3508	9TG111, 193, 204, 205, 208, 209, 211, 212, 215, 218, 219, 224-226, 234, 247, 258-261, 268, 274, 275 2TJ158, 160, 161, 163
G3512	5JD28, 51 7NJ202, 228, 243, 287-289, 534, 577, 578, 588, 590, 592, 594, 598, 609, 626, 671, 674, 676, 680, 685, 711-715, 768-770, 890, 891
G3516	4EK494, 628, 671, 672, 698, 1465, 1558-1561, 1563, 1568-1570, 1572-1574, 1577, 1579, 1582, 1597, 1613, 1620, 1666, 1700, 1703, 1737, 1753, 1762, 1768, 1774, 1780, 1791, 1840, 1896, 1903, 1906, 1911, 1930, 2054, 2099, 2109, 2184, 2185, 2211, 2214-2216, 2252, 2256, 2258, 2277, 2281, 2285-2288, 2294, 2296, 2308, 2309, 2315, 2316, 2319, 2322, 2324, 2326, 2336, 2358, 2423, 2424, 2428, 2444, 2448, 2461, 2463, 2467, 2480, 2529, 2530, 2540-2542, 2547, 2553, 2554, 2558-2560, 2574, 2575, 2577, 2583, 2611, 2621, 2625, 2626, 2637, 2653, 2654, 2675-2679, 2711, 2779, 2785, 2796, 2797, 2819-2822, 2824-2826, 2829, 2831, 2860, 2862, 2864, 2865, 2869, 2870, 2872, 2874, 2876, 2880, 2881, 2901, 2907, 2915, 2935, 2937, 3028, 3068, 3085, 3086, 3088-3090, 3092, 3093, 3095, 3117, 3122, 3128, 3147, 3153, 3196, 3211, 3213, 3222, 3239, 3281, 3284, 3300, 3349, 3368, 3414, 3417, 3422, 3427, 3433, 3434 CEY154-156

PARTS NEEDED

No parts needed.

ACTION REQUIRED

See attached check list and test procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1.0	0	0	0	0
NOTE: This is a 1.0- hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE EMCPII PANEL

MODELS INVOLVED - CERTAIN G3508, G3512, AND G3516 GAS ENGINES

Dear Caterpillar Product Owner:

The predetonation shut down interconnect wiring to the EMCPII panel may be miswired, and the unit may not shut down if predonation is determined by the EIS module. Certain G3508, G3512, and G3516 engines may need to be rewired on the products listed below. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated January 6, 2003 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 January 6, 2003 Service Letter

Rework Procedure

Detonation Shutdown Wiring Check:

Equipment: 3500 Gas Engine Generator Sets with EMCPII control panels

Panel Part# Affected: 1196031 and 1366924

Abbreviations:

EIS-electronic ignition system(engine mounted)
GSC-generator set control (panel mounted)
GTS-generator terminal strip (connection cabinet mounted, left side of generator box)

Wiring Diagram:

1196031 panel associated wiring diagram 1198883sht4
1366924 panel associated wiring diagram 1198883sht4

Issue: Some G3500 generator sets may have the detonation shutdown signal incorrectly wired from the EIS (electronic ignition system) to the EMCPII control panel SW3 spare shutdown terminal 25 on the GSC (generator control module) in the EMCPII.

Figure 1

To check, verify the wiring from pin F of the EIS module to terminal GTS 256 position. Also, verify the wiring from the GTS 256 to the GSC terminal 25. The interface is through the forty pin connector pin 32 on drawing 1472921 sheet 2.

After verifying wiring, perform a detonation shutdown check by tapping near the detonation sensor until detonation shutdown occurs. Verify the EMCPII OP6-0 setpoint SP05, Spare Input 3 Active State, is set to 0 (active state is Low) and not set to 1 (active state is high). Verify that ECMPII OP6-0 setpoint SP06, Spare Input 3 Response, is set to 0 for shutdown.