PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPACE HEATER RELAY ON CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B, G3508, G3512, G3516, AND G3516B GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPACE HEATER RELAY ON CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B, G3508, G3512, G3516, AND G3516B GENSETS

Usage:

SEBE8260-01

January 13, 2003
(Revised April 2003)
U-18
A-14
D-14
O-17

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*Before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE SPACE HEATER RELAY ON CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B, G3508, G3512, G3516, AND G3516B GENSETS
4453		PS41169

NOTE: This Program can 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 "PS41169" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "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 13, 2003 Service Letter. Changes have been made to the Rework Procedure.

TERMINATION DATE

January 31, 2004

PROBLEM

The 1220335 Space Heater Relay fails when 120 volt input is used for supply power. A new Allen Bradley Relay and Socket must be used instead of the existing TAPCO arrangement.

AFFECTED PRODUCT

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Model	Identification Number
3508	3LS202, 214-215, 219, 225-227 5XM23, 24, 25, 26, 27, 30, 31 70Z1049-1051 CNF203, 205, 209-211, 219, 225, 229, 233-234, 242-243, 277-278, 284-285, 288, 290-292, 297, 300, 303, 305, 312, 318
3508B	2HW119, 120 4GM289, 293, 303, 306, 307, 310-313, 316, 324-328, 330, 333, 337, 340, 341, 345, 352-353, 357, 358, 360, 363, 375, 381-383, 393, 394, 401, 403, 408, 414-415, 421, 429, 434, 437, 444, 458, 463, 468, 470, 472, 474-476, 483, 485, 487, 492-495, 502, 503, 509, 511-514, 517, 518, 525, 526, 536, 542, 544, 553, 555-558, 563, 566-568, 577, 581, 582, 585, 596, 599, 606, 607, 613, 616, 626, 627, 629, 630, 632, 634-636, 639, 641, 644, 645, 647, 648, 650-653, 658-663, 666, 667, 669, 671, 672, 674, 676, 682-690, 692, 695, 697, 698, 700-702, 705-717, 719, 721, 722, 724, 725, 727, 728, 729, 730, 731, 734, 735, 736, 742 6PN418, 421, 422, 423, 428, 430, 433, 439, 442, 448, 449, 452, 453, 455, 473, 475, 476, 477, 478, 493, 518, 519, 544, 545, 555, 558, 559, 572, 573, 577, 591, 604, 613, 614, 620, 625, 630, 640, 686, 687, 690, 692, 694, 705, 707, 708, 710, 712, 715, 718, 719, 721, 722, 728, 739, 747, 751, 757, 758, 765, 767, 774, 777, 783, 785 BGX107-108 CNB201-206, 208-220, 222, 224, 227-228, 233-234, 239, 242-245, 247, 249-250, 252-255, 260, 265-267, 269-270, 284, 289-293, 295-296, 299-301, 303-305, 314-315, 321-323, 326, 328-330, 334-336, 339-341, 348-350, 354, 358-362, 364-365, 368, 370-371, 375, 378, 380, 385, 389, 391-392, 394-396, 399, 403, 410, 425-426, 435-448, 451, 460-463, 465, 471, 473, 475-478, 486, 488, 490, 496-503, 508, 516-519, 528, 530-531, 533, 535, 550
3512	24Z9768-9771, 9773, 9775, 9776, 9779, 9780, 9782, 9783, 9785, 9786, 9790, 9791, 9796, 9803, 9805, 9807, 9810, 9811, 9821, 9822, 9824, 9826, 9830, 9834, 9838, 9846, 9847, 9849, 9854, 9861, 9867, 9873, 9882, 9883, 9894, 9902, 9905, 9909, 9911, 9913, 9926, 9927, 9930, 9933, 9935, 9939, 9940, 9944, 9945, 9949, 9952, 9954, 99672, 9976, 9988, 10005, 10006, 10009, 10011-10013, 10018-10020, 10022-10023, 10025, 10027, 10034-10035, 10037, 10039-10041, 10045-10046, 10052, 10084 3MS166-167, 169, 171, 173, 179-180, 182, 185-186, 188, 192-193, 204, 209-211, 215, 220-221, 227, 231 67Z1762, 1819, 1825, 1842, 1844, 1856, 1882 6PM40, 48, 49, 50, 51, 52 7NJ594 CMJ118, 121-123, 125-127, 129-130, 132, 132, 139-147, 149-150, 167, 172, 175, 182-187, 189, 191, 195-211, 215-222, 227-228, 234-237, 239, 243-246, 249-250, 253, 260, 263, 270, 273, 279, 281-283, 285, 287-288, 293-297, 308-312, 316, 321, 325, 327-332, 334-339, 341, 348-349, 352, 354-356, 361, 363, 370, 374, 377-379, 382-385, 391, 410, 422 FDR306-312
3512B	5AW77, 90-112, 122, 126-129 6WN183, 184, 185, 199, 202, 203, 210, 214, 219, 235, 241, 248, 251, 252, 253, 258, 260, 261, 262, 268, 269, 276, 277, 286, 287, 296, 297, 303, 304, 305, 317, 325, 326, 331, 344, 346, 347, 349, 350, 352, 356, 357, 366, 368, 369, 370, 378, 379, 380, 381, 382, 384, 385, 388, 389, 390, 392, 402, 403, 404, 407, 409, 418, 423, 426, 427, 428, 429, 430, 431, 432, 435, 436, 438, 441, 442, 443, 455, 456, 457, 458, 459, 460, 461, 462, 463, 464, 465, 466, 467, 469, 470, 473, 475, 476, 479, 480, 481, 482, 483, 486, 488, 493, 495, 496, 497, 504, 505, 506, 507, 513, 514, 515, 518, 519, 520, 521, 522, 523, 524, 525, 527, 528, 529, 532, 535, 536, 537, 539, 541, 542, 545, 549, 550, 551, 552, 553, 559, 560, 561, 563, 564, 565, 567, 571, 572, 575, 578, 579, 581, 582, 583, 584, 591, 595, 600, 601, 602, 603, 604, 605, 606, 608, 611, 613, 614, 615, 616, 619, 620, 621, 622, 623, 626, 627, 628, 630, 632, 633, 634, 643, 648, 649, 664, 665, 673, 675, 679, 682, 683, 685, 686, 687, 688, 689, 690, 693, 694, 695, 696, 697, 700, 701, 704, 706, 709, 710, 711, 712, 724, 726, 729, 730, 732, 734, 735, 736, 737, 738, 743, 744, 745, 746, 748, 751, 752, 755, 756, 758, 760, 762, 764, 765, 767, 768, 770, 773, 774, 777, 782, 783, 784, 785, 786, 789, 791, 792, 793, 794, 796, 797, 798 8RM307, 316, 317, 324, 329, 330, 331, 332, 351, 352, 353, 354, 360, 370, 395, 396, 402, 406, 413, 434, 446, 447, 448, 449, 451, 452, 457, 466, 470, 490, 496, 498, 518, 520, 526, 529, 539, 545, 547, 549, 553, 554, 556, 559, 560, 565, 576, 577, 584, 599, 604, 605, 606, 608, 613, 625, 636, 637, 638, 644, 656, 657, 663, 664, 665, 667, 668, 669, 671, 672, 675, 676, 677, 678, 680, 682, 683, 684, 685, 686, 687, 688, 689, 690, 691, 692, 693, 694, 695, 696, 698, 701, 702, 704, 705, 709, 710, 712, 713, 727, 728 CTB162 BRK204, 208-216, 218-220 CMC114-115, 118, 129-132, 140-146, 148-149, 152-162, 165-166, 168-171, 180-185, 187-188, 191-193, 195-200, 204-205, 207-208, 212-213, 215-217, 219-220, 223, 225-227, 232-233, 235-238, 241, 245, 249-258, 264-266, 268-277, 280-281, 285-306, 308, 312-313, 322-326, 328-333, 335-339, 341, 344, 347, 366, 369, 372, 394-395, 400, 402, 404, 410-411, 414, 418-421, 423-427, 442-447, 450, 453-455, 460-464, 466-467, 469-481, 485, 487, 490-496, 500-502, 512, 515, 517-518, 525, 532-536, 538-541, 544-545, 547-550, 554
3516	4XF720, 734, 735, 737, 738 25Z5946, 6077, 6079, 6081-6082, 6085-6087, 6091, 6101, 6105-6106 6138, 6142-6146, 6150, 6160, 6172-6173, 6175, 6185, 6219, 6227-6231, 6238, 6248, 6250, 6297, 6305, 6314-6315, 6354-6356, 6358-6359, 6401, 6404, 6427, 6429, 6431, 6445-6446, 6451-6454, 6481, 6499, 6507, 6522, 6526, 6528, 6529, 6547, 6560, 6565, 6606, 6608, 6613-6616, 6648, 6654, 6657-6658, 6660-6662, 6664, 6728, 6732-6733, 6751, 6769, 6772, 6782, 6786, 6851, 6853, 6859, 6871, 6879, 6888, 6890, 6900, 6911, 6914, 6919-6920, 6922-6923, 6930-6935, 6939-6943, 6948, 6952, 6954, 6956, 6961-6962, 6964, 6966-6968, 6970-6973, 6978-6985, 7000-7002, 7005-7006, 7010-7015, 7017-7021, 7023, 7027, 7029-7033, 7036-7037, 7049, 7055-7056, 7058, 7062 4EK1737, 1753, 1762, 1768, 1780, 1791, 1840, 1896, 1903, 1911, 2326, 2574, 2577, 2621, 2625-2626, 2797, 2862, 2865, 2872, 2874, 2876-2877, 2879, 2882, 2910, 3153, 3349, 3432, 3437 5SJ216, 667, 674, 689, 690, 713, 717, 718, 725, 732 73Z916, 917, 932, 933, 934, 936, 943, 944, 945, 949, 950 7KM39, 40, 50 CAL133, 142 CMD140, 143, 149, 158-163, 165, 167-177, 179-192, 194, 196-198, 200, 205, 206, 208, 219, 221, 226, 228-230, 233, 236, 237, 248, 249, 251, 252, 260, 272
3516B	2JW193, 197-200, 207-216, 229-232, 234-236, 238, 240, 241, 243-245, 247-248, 250-272, 274-276, 280, 287-291, 307-309, 311-312, 316, 319-321, 323-324, 326-327, 329, 331-333, 335-337, 339, 346-349, 351, 353-354, 357-358, 360, 362-364, 374 6HN214, 216-219, 224, 238, 240, 241, 250, 251, 264, 265, 266, 269, 280, 281, 283, 287, 290, 291, 292, 298, 301, 302, 306, 310, 312, 313, 328, 329, 330, 331, 332, 333, 337, 339, 341, 342, 355, 357, 358, 359, 386, 389, 392, 394, 396, 397, 402, 409, 420, 423, 429, 430, 436, 437, 439, 440, 441, 444, 445, 452, 453, 455, 457, 464, 465, 466, 467, 468, 474, 476, 477, 487, 489, 490, 493, 494, 499, 500, 502, 505, 507, 508, 513, 514, 515, 518, 521, 522, 527, 528, 529, 530, 531, 532, 533, 534, 536, 537, 538, 540, 541, 546, 549, 550, 552, 554, 556, 557, 558, 565, 566, 572, 577, 580, 582, 583, 584, 585, 587, 594, 608, 609, 611, 612, 613, 614, 615, 619, 620, 621, 622, 623, 624, 628, 629, 631, 633, 634, 636, 637, 638, 640, 641, 643, 644, 645, 646, 647, 649, 650, 651, 652, 653, 654, 655, 656, 657, 658, 659, 665, 670, 672, 675, 676, 677, 678, 679, 681, 682, 684, 685, 693, 695, 696, 700, 701, 703, 705, 706, 713, 716, 717, 719, 721, 722, 723, 724, 726, 728, 730, 731, 732, 737, 740, 743, 746, 748, 750, 751, 752, 753, 754, 756, 757, 758, 760, 763, 765, 769, 770, 773, 774, 776, 777, 778, 779, 780, 782, 783, 784, 785, 786, 787, 788, 789, 791, 794, 796, 798, 800, 801, 802, 803, 811, 813, 815, 820, 823, 825, 826, 827, 828, 830, 832, 834, 835, 837, 838, 839, 841, 842, 843, 844, 845, 846, 847, 848, 849, 850, 851, 853, 855, 856, 857, 862, 863, 865, 866, 867, 868, 869, 870, 872, 873, 874, 875, 876, 877, 878, 879, 880, 881, 886, 887, 888, 889, 890, 893, 894, 895, 896, 897, 898, 899, 901, 902, 903, 904, 906, 908, 909, 910, 912, 913, 915, 916, 917, 918, 919, 920, 922, 924, 925, 928, 930, 931, 947, 950, 955, 964, 968, 969, 970, 971, 972, 973, 974, 975, 976, 977, 978, 980, 981, 982, 983, 984, 986, 987, 989, 990, 991, 992, 993, 994, 995, 997, 1001, 1003, 1004, 1005, 1007, 1008, 1010, 1011, 1012, 1014, 1015, 1017, 1019, 1021, 1022, 1023, 1024, 1025, 1028, 1029, 1030, 1031, 1032, 1033, 1040, 1041, 1046, 1047, 1048, 1051, 1053, 1054, 1056, 1058, 1059, 1060, 1064, 1065, 1066, 1067, 1068, 1072, 1075, 1076, 1077, 1078, 1079, 1080, 1081, 1086, 1087, 1088, 1089, 1090, 1095, 1101, 1102, 1110, 1111, 1112, 1113, 1114, 1115, 1116, 1117, 1119, 1124, 1125, 1126, 1132, 1133, 1135, 1137, 1138, 1139, 1140, 1141, 1142, 1143, 1144, 1145, 1146, 1147, 1148, 1149, 1150, 1151, 1153, 1154, 1155, 1156, 1159, 1160, 1162, 1164, 1165, 1166, 1167, 1168, 1170, 1174, 1175, 1176, 1177, 1180, 1183, 1184, 1185, 1186, 1187, 1188, 1189, 1190, 1191, 1192, 1193, 1195, 1196, 1197, 1198, 1199, 1200, 1201, 1203, 1204, 1207, 1208, 1209, 1210, 1215, 1216, 1217, 1220, 1222, 1226, 1227, 1232, 1234, 1237, 1238, 1242, 1243, 1245, 1247, 1251, 1254, 1255, 1256, 1257, 1260, 1261, 1262, 1263, 1264, 1270, 1271, 1272, 1273, 1277, 1278, 1279, 1284, 1285, 1286, 1287, 1289, 1293, 1294, 1295, 1296, 1298, 1299, 1300, 1302, 1303, 1304, 1305, 1306, 1307, 1309, 1310, 1311, 1312, 1314, 1315, 1316, 1317, 1318, 1319, 1320, 1321, 1322, 1324, 1325, 1327, 1328, 1330, 1331, 1332, 1333, 1334, 1335, 1336, 1338, 1339, 1340, 1341, 1342, 1346, 1347, 1349, 1353, 1354, 1355, 1358, 1359, 1361, 1363, 1364, 1366, 1367, 1368, 1369, 1370, 1373, 1375, 1377, 1381, 1384, 1386, 1387, 1389, 1391, 1393, 1394, 1396, 1402, 1404, 1408, 1410, 1412, 1414, 1415, 1421, 1422, 1423, 1425, 1429, 1430, 1431, 1434, 1435, 1436, 1437, 1438, 1456, 1459, 1469, 1470, 1476, 1479, 1480, 1486, 1487, 1488, 1489, 1490, 1491, 1493, 1496, 1497, 1498, 1500, 1502, 1503, 1505, 1506, 1507, 1508, 1509, 1511, 1514, 1516, 1518, 1521, 1522, 1523, 1524, 1525, 1528, 1529, 1533, 1537, 1540, 1541, 1546, 1547, 1571, 1572, 1577, 1582, 1583, 1587, 1589, 1590, 1591, 1592, 1595, 1600, 1601, 1602, 1611, 1637, 1644, 1650, 1652, 1659, 1661, 1663, 1664, 1665, 1666, 1667, 1670, 1672, 1673, 1674, 1676, 1677, 1678, 1682, 1683, 1684 7RN574, 577, 578, 580, 589, 609, 616, 618, 620, 621, 622, 623, 624, 625, 626, 627, 628, 629, 630, 631, 632, 633, 634, 635, 636, 664, 669, 671, 672, 673, 674, 676, 720, 724, 728, 729, 730, 762, 763, 777, 779, 781, 798, 799, 808, 809, 813, 814, 815, 817, 819, 827, 828, 837, 838, 850, 852, 897, 899, 905, 918, 919, 920, 921, 927, 928, 929, 931, 934, 935, 940, 943, 944, 945, 946, 947, 951, 952, 953, 959, 960, 961, 962, 963, 964, 965, 966, 967, 968, 971, 978, 979, 981, 982, 984, 990, 1002, 1005, 1006, 1007, 1011, 1015, 1016, 1019, 1020, 1021, 1023, 1025, 1027, 1029, 1035, 1036, 1041, 1042, 1046, 1047, 1048, 1049, 1050, 1051, 1055, 1056, 1058, 1059, 1060, 1061, 1064, 1065, 1066, 1067, 1068, 1069, 1073, 1076, 1078, 1079, 1084, 1086, 1088, 1109, 1119, 1120, 1121, 1122, 1123, 1125, 1126, 1127, 1132, 1133, 1136, 1138, 1140, 1142, 1144, 1146, 1147, 1153, 1154, 1161, 1162, 1163, 1164, 1168, 1175, 1185, 1191, 1196, 1200, 1207, 1208, 1215, 1217, 1218, 1221, 1222, 1227, 1229, 1232, 1234, 1240, 1243, 1254, 1289, 1295, 1296, 1297, 1349, 1354, 1355, 1357, 1358, 1362, 1374, 1375, 1382, 1384, 1389, 1393, 1399, 1410, 1412, 1425, 1427, 1436, 1449, 1485, 1486, 1491, 1492, 1496, 1503, 1504, 1536, 1539, 1551, 1555, 1556, 1559, 1561, 1563, 1574, 1616, 1633, 1639, 1640, 1643, 1669, 1673, 1676, 1677, 1719, 1726, 1727, 1729, 1731, 1732, 1733, 1734, 1749, 1755, 1765, 1774, 1776, 1779, 1819, 1824, 1825, 1826, 1827, 1830, 1831, 1835, 1838, 1840, 1857, 1860, 1861, 1863, 1871, 1872, 1873, 1874, 1879, 1883, 1901 BPJ353-357, 385 FDN107-109, 115-116, 119-120, 124, 126-130, 134-135, 137, 141, 144-145, 147, 151-152, 163, 165-168, 170-172, 174, 177, 180-195, 207, 209, 213-214, 216, 218, 226-230, 232, 234, 240-241, 252-253, 259-260, 264-277, 279-298, 306, 324, 328, 362, 382, 385, 389-391, 393-396, 399-401, 405-424, 427-432, 434-455, 465, 467-470, 481, 490-498, 503-505, 510-512, 515, 522, 524-533, 535, 544-545, 547-548, 553-554, 569, 571-573, 577-582, 586-587, 590-592, 594-596, 598, 603-625, 627-629, 648, 650-653, 657, 659, 704-705, 714-723, 728, 730, 734, 746-753, 755, 761-762, 766, 768, 775, 801, 807, 809-810, 813, 818-821, 823, 832-838, 844-846, 848-850, 852, 860, 870-878, 884, 886-891, 895, 897-898, 908-911
G3508	9TG215, 218, 219, 224, 225, 226, 247, 258, 259, 260, 261, 274 CPJ303, 308-309
G3512	CRN112-116, 144
G3516	CSZ254, 261, 277, 279-282, 284-288, 313-316, 318-320, 329, 368-369, 386-387, 406, 528
G3516B	CTA149, 150 CSC126, 142-144

PARTS NEEDED

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Qty	Part Number	Description
2	1292199	HARNESS AS
1	1293497	HARNESS AS
1	2210753	RELAY
1	2210754	SOCKET-RELAY
1	2210755	SPRING-RELAY

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Product smu	Caterpillar		Dealer Suggested		Customer Suggested
Product smu	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-8760 hours	100%	1.0	0	0	0	0
NOTE: This is a 1.0?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Space Heater Relay

Turn off all supply power (AC & DC), prevent the engine from starting, and lock out the equipment before working on or inside the equipment. Only qualified Caterpillar technicians must service this equipment. Observe all safety procedures as indicated in Caterpillar manuals.

Use the properly rated voltage-sensing device in order to confirm power is off.

NOTE: For steps 2?5, refer to Figure 1.

Disconnect customer power supply from terminals 5 & 6.
Disconnect the old wiring harnesses, 1292199 and 1293497, from the relay assembly and associated terminal strips.
Remove the din rail end stop from the 1705397 terminal strip. The end stop is located next to the space heater relay.
Remove the 115-7947 relay and the 1291992 Relay Assembly from the 1705397/">170-5397 terminal strip. Dispose of relay and relay assembly appropriately.

NOTE: For steps 6?9, refer to Figure 2.

NOTE: Figure 2 as shown is wired for 240V AC. For 115/120V AC, do the following:

Remove the jumper between H2 and H3 on the main terminal strip.
Connect second wiring harness (1292199) between the main terminal strip and the 2210754 socket relay. Connect H2 to terminal 3 and H3 to terminal 1.

Install the 2210754 Socket Relay, the 2210753 Control Relay, and the 2210755 Spring Relay onto the 1705397 Terminal Strip.
Install the Din Rail End Stop on the Terminal Strip next to the relay installed in step 6.
Connect the new Wiring Harnesses, 1292199 and 1293497.

NOTE: The new wiring harness are 50 mm longer.