Product Improvement Program for adding the ECM reset timer relay scheme on certain 3456 Common Design Generator Sets Caterpillar

Product Improvement Program for adding the ECM reset timer relay scheme on certain 3456 Common Design Generator Sets

Usage:

SEBE9821-00

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20Dec2005

U-516

A-512

D-513

O-513

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR ADDING THE ECM RESET TIMER RELAY SCHEME ON CERTAIN 3456 COMMON DESIGN GENERATOR SETS
4493		PI10502

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10502" 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 "PI10502" 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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PROBLEM

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Some 3456 Common Design genset packages are not equipped with an automatic ECM reset scheme. Without the reset scheme, the ECM is unable to cycle power after any engine shut down fault preventing the genset from restarting. Also, the capability to annunciate a "Not in Auto" condition is disabled.

AFFECTED PRODUCT

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Model	Identification Number
3456	C3G00123, 125-145, 149-524 C4G00123, 126-145, 147-195, 200-230, 232-378

PARTS NEEDED

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Qty	Part Number	Description
1	2140491	RELAY - TIMER
1	2770304	HARNESS AS

ACTION REQUIRED

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Install new timer relay and wire harness to provide the ECM reset scheme.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive an Owner Notification.

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR ADDING THE ECM RESET TIMER RELAY SCHEME

MODELS INVOLVED - CERTAIN 3456 COMMON DESIGN GENERATOR SETS

Dear Caterpillar Product Owner:

A new ECM reset timer relay needs to be installed on the product(s) listed below. When the E-stop is actuated, inadvertently or on purpose, there will not be an annunciation of the event and the genset will not start until reset. In critical applications (such as life support, etc.) the genset may not function when required, which may result in personal injury or death.

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 20Dec2005 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 20Dec2005 Service Letter

Rework Procedure

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1) Depress emergency stop pushbutton, place engine control switch (ECS) in "STOP" or "OFF / RESET" position, implement lockout / tagout procedure. Isolate 24 Vdc source from package.

2) Locate DC terminal strip and remove bridge clip. DC terminal strip is numbered left to right. See Image 1.1.1

Image1.1.1

3) Install Relay Group 268-1457, Engineering Change Level 01. See Image 1.2.1. Refer to table in Image 1.2.2 for wiring instructions.

Image1.2.1

Image1.2.2

*Door terminal strip is numbered right to left.

For additional information related to EMCPII installations, refer to schematic 234-3202, Engineering Change Level 06. For additional information related to EMCPII+ installations, refer to schematic 235-0745, Engineering Change Level 07.

4) Before installing timer, set timer coil operating voltage to 24Vdc. See Image 1.3.1.

5) Set timer top dial to 0.3, see Image 1.3.1.

6) Set timer middle dial to 10 S, see Image 1.3.1.

7) Set timer bottom dial to E, see Image 1.3.1.

Image1.3.1

8) Apply 24Vdc source to package, remove lockout / tagout devices, reset emergency stop pushbutton to normal operating position.

9) Place ECS in "START" position. Engine should start.

10) Allow engine to run for 30 seconds, then depress emergency stop pushbutton. Engine should stop.

11) Once engine stops, reset emergency stop pushbutton to normal operating position.

12) Place ECS in "STOP" or "OFF / RESET" position.

13) Verify "Not In Auto" condition is properly displayed locally and, if applicable, remotely.

14) Place ECS in "START" position. Engine should start.

15) Allow engine to run for 30 seconds, then place ECS in "STOP" or
"OFF / RESET" position. Engine should stop.

16) Place ECS in "AUTO" position and test package for automatic starting.

17) Allow engine to run for 30 seconds, then place ECS in "STOP" or
"OFF / RESET" position.

18) Place ECS in desired position before leaving installation.