PRODUCT SUPPORT PROGRAM FOR UPDATING THE START/STOP RELAYS ON CERTAIN 3412 GENERATOR SETS

Usage:

SEBE8567-01

November 12, 2003
(Revised April 2004)
U-309
A-212
D-229
O-258

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE START/STOP RELAYS ON CERTAIN 3412 GENERATOR SETS
7418		PS41463

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 "PS41463" 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 November 12, 2003 Service Letter. Changes have been made to the Affected Product.

TERMINATION DATE

November 30, 2005

PROBLEM

The start/stop relays on certain 3412 generator sets need to be updated. Failure could prevent the genset from starting or stopping.

AFFECTED PRODUCT

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Model	Identification Number
3412	9EP174, 179, 200, 265, 267, 285, 312, 322, 323, 325-328, 332, 334, 337-339, 342-344, 346, 349-351, 353-355, 358-361, 364-370, 373, 374, 377, 379-383, 389-392, 397, 399, 406-410, 413, 417, 419, 420, 426-429, 431-439, 442, 443, 446, 448-454, 460, 461, 464, 465, 468, 474, 479, 482-483, 485-486, 488, 491, 493, 496, 498-499, 501, 503-504, 506-508, 512-513, 515-518, 520, 522-523, 527-529, 531, 535-538, 544, 546-548, 555, 559, 560, 562, 566, 567, 571, 575, 579-582, 587, 588, 590-592, 598-602, 604-606, 608, 612, 613, 615, 624, 625, 629-632, 635, 638-640, 645, 648, 650, 652, 654-657, 662, 664, 670, 673-677, 679, 690, 691, 693, 694, 697, 700-705, 709, 712, 723, 726, 727, 729, 732, 733, 736-740, 742, 743, 745-746, 750-753, 771, 782, 785-786, 788-791, 794-795, 798, 800-801, 804, 825, 828-829, 846, 848, 851-852, 855-859, 862, 865, 867-868, 870, 873-874, 878-879, 884, 886, 888, 894-896, 898, 900, 904-906, 908, 912, 917, 920-922, 925-926, 929-931, 933-934, 937, 941, 942, 944-951, 953, 955-963, 966, 969, 971, 975-978, 993-994, 1009, 1013, 1014, 1031, 1046, 1051-1053, 1056, 1059-1060, 1064, 1064, 1071, 1073-1082, 1085, 1087-1088, 1092, 1094-1095, 1097-1114, 1121, 1123, 1127, 1130-1136, 1139, 1141-1142, 1147, 1155-1156, 1158-1159, 1165, 1169-1170, 1172, 1177-1187, 1190-1218, 1207, 1223-1226, 1229-1230, 1232-1241, 1245, 1247-1255, 1261, 1288, 1298, 1299, 1301-1302, 1315-1317, 1319, 1323, 1327, 1329-1347, 1349, 1355, 1359-1363, 1366-1367, 1372-1373, 1375, 1382-1385, 1393, 1394, 1397, 1401, 1405-1406, 1414-1415, 1417-1421, 1429-1430, 1436, 1440, 1442, 1446, 1449, 1454, 1460, 1463-1465, 1468-1469, 1471, 1473, 1483, 1486, 1488, 1491, 1493, 1496, 1502-1505, 1512, 1519, 1521-1522, 1526-1527, 1533-1534, 1539, 1542, 1543, 1545, 1547, 1550, 1551, 1556, 1557, 1559, 1562, 1563, 1570-1571, 1573, 1577, 1579, 1582, 1584, 1586, 1588-1591, 1595-1596, 1598, 1601, 1609-1610, 1612-1615, 1617-1619, 1621, 1623, 1625-1626, 1629, 1631, 1633, 1636-1637, 1640-1646, 1649-1651, 1653-1655, 1661-1665, 1667, 1672-1675, 1679, 1683-1684, 1692, 1694, 1702, 1704, 1706, 1708-1709, 1717-1718, 1721, 1733-1734, 1738, 1741-1743, 1746, 1749, 1754, 1756, 1759, 1764-1765, 1767, 1773, 1780-1781, 1783, 1785-1786, 1789, 1797-1800, 1803-1805, 1807, 1809, 1814-1817, 1822-1823, 1827, 1829, 1832, 1835, 1837-1840, 1843, 1846, 1848, 1850-1851, 1854-1855, 1857, 1859-1861, 1863, 1865, 1876-1877, 1881, 1884, 1886-1888, 1890, 1896, 1899-1902, 1904-1905, 1907-1909, 1911-1912, 1915, 1921-1922, 1925-1929, 1933, 1935-1936, 1938-1941, 1946, 1948-1950, 1952, 1956, 1958-1959, 1962-1963, 1965, 1968-1971, 1987, 1989-1990, 1992, 1995-1996, 1998, 2000-2001, 2004-2006, 2008, 2012, 2016-2019, 2022-2023, 2025-2029, 2031, 2033, 2035, 2040-2044, 2046, 2054-2061, 2066, 2068-2069, 2071, 2076, 2078-2079, 2081-2083, 2085-2086, 2095, 2099, 2101-2102, 2106-2107, 2110-2111, 2113-2114, 2118-2120, 2124, 2133-2142, 2149-2151, 2155-2157, 2162, 2167, 2169-2170, 2176-2177, 2179, 2182-2184, 2187-2189, 2192, 2196, 2199, 2201-2202, 2204-2205, 2210-2211, 2213, 2216-2217, 2224, 2228, 2230, 2232-2234, 2236, 2240-2241, 2245, 2249-2250, 2252-2255, 2260, 2264-2266, 2269, 2271-2272, 2274-2275, 2277-2278, 2280, 2285, 2287, 2289, 2293, 2295, 2300-2302, 2304, 2307-2308, 2314-2315, 2318-2319, 2321, 2323, 2327, 2329, 2331, 2333, 2336-2339, 2342-2343, 2349-2350, 2352-2353, 2355, 2358-2362, 2365-2366, 2373, 2376-2377, 2379-2380, 2385, 2390-2391, 2393-2396, 2398-2399, 2401-2407, 2412-2413, 2415-2417, 2420, 2424, 2426, 2431, 2434, 2436-2437, 2439, 2442-2443, 2445, 2447-2448, 2450-2453, 2458, 2460-2463, 2465, 2467, 2469, 2471, 2473-2476, 2479-2482, 2484-2487, 2489, 2491, 2499-2502, 2504-2505, 2507-2508, 2510, 2513, 2516-2519, 2525-2529, 2531, 2532, 2535-2538, 2540, 2542, 2545, 2546, 2549, 2552, 2558, 2560, 2561, 2563, 2564, 2567, 2569, 2570, 2572, 2575-2577, 2580, 2587, 2588, 2590, 2591, 2596, 2598, 2599, 2600, 2602, 2607-2610, 2614-2616, 2619, 2622, 2623, 2630-2632, 2635, 2639, 2640, 2642, 2647, 2649-2651, 2653, 2654, 2657, 2660-2663, 2666, 2668, 2672-2673, 2675-2676, 2689-2690, 2692-2694, 2696, 2699, 2704, 2708, 2710-2711, 2713, 2717-2718, 2723, 2725-2727, 2729-2737, 2741, 2745-2746, 2749, 2752-2754, 2761, 2762, 2765-2767, 2769, 2771, 2774, 2779-2780, 2782-2785, 2789-2794, 2796-2799, 2805, 2809-2811, 2813-2814, 2817-2818, 2821, 2827, 2834-2835, 2845-2849, 2855, 2858, 2861-2863, 2866-2868, 2870, 2872-2874, 2876, 2879-2881, 2883-2886, 2888-2891, 2895-2898
3412C	BCW158, 169, 172, 175, 178, 183, 185-186, 190-195, 197-201, 206-207, 209, 212-213, 216, 219, 228-233, 237-238, 240-243, 245, 247-248, 252-255, 260, 263-267, 269-270, 274, 276, 278-280, 283-286, 290, 293-295, 297, 302-304, 306, 309-310, 314, 323-324, 326-327, 347, 355, 356, 358-374, 376-379, 382-383, 386-390, 394-398, 401-403, 406-409, 412-414, 418-420, 422, 424-426, 428, 431-436, 439, 441, 443, 444, 447, 450-460, 463-468, 471-480, 483-484, 490-492, 496, 499, 501-503, 505, 511, 513-514, 517, 519, 521-522, 524-525, 527-532, 534-535, 538, 540, 542-547, 549-552, 559-565, 567-572, 578-580, 583-584, 586-589, 592, 594-597, 600, 602, 604, 605, 607, 609, 615, 618-622, 624-625, 628-630, 634, 636-638, 643-644, 646-652, 654, 656-660, 662, 665, 667, 668, 670, 672-673, 675, 677-678, 680-683, 686, 687, 689, 692, 694-696, 699-701, 703-710, 712, 715, 718, 720, 722-726, 728, 729

PARTS NEEDED

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Qty	Part Number	Description
2	1G6420	SPRING-HOLD
2	1157948	SOCKET-RELAY
2	1660391	RELAY AS

NOTE: To be provided by the dealer, a quantity of 8 insulated Ferrell part# 1093038 or equivalent, and 1 Din rail 35 mm wide x 127 mm long are also needed.

ACTION REQUIRED

See the attached Rework Procedure.

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
0-24 mos	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

Turn off all supply power, prevent the engine from starting and lock out the equipment before working on the equipment or inside equipment. Only qualified Caterpillar technicians must service this equipment. Always use the properly rated voltage-sensing device in order to confirm power is off. Replace all devices, doors, and covers before turning power on to this equipment.

Open the junction box on the lower left side of the generator. See Illustration A.

Illustration A ? Junction Box Location

Remove the wires connected to the PEEC and EDSR relays (1857236). See Illustration B.

Illustration B ? Junction Box Components

Remove both relays (1857236) from the junction box
Replace the din rail in the center of the box with a piece that is 35 mm wide and 127 mm long.
Add the 1st end block and the terminal blocks to the left side of the din rail. See Illustration C.
Attach two new relay sockets (1157948) to the din rail. See Illustration C.
Place the 2nd end block on the right end of the din rail. See Illustration C.
Place the new relay (1660391) into relay socket (1157948).
Replace all wire ends that will connect to the new relay with the proper insulated Ferrell connector.
Land all the wire connections using Table A and Illustration C.

Illustration C ? New Relay Connection Points

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PEEC Relay			ESDR Relay
Wire#	Old Termination	New Termination	Wire#	Old Termination	New Termination
2	PEEC 86	PEEC 14	27	ESDR 87	ESDR 1
10	PEEC 85	PEEC 13	2	ESDR 30	ESDR 9
1E	PEEC 30	PEEC 9	3	ESDR 85	ESDR 13
PPOS	PEEC 87	PEEC 5	2	ESDR 86	ESDR 14