PRODUCT IMPROVEMENT PROGRAM FOR JACKET WATER HEATER CONTACTOR WIRING AND LOGIC ON CERTAIN C27 GENSETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR JACKET WATER HEATER CONTACTOR WIRING AND LOGIC ON CERTAIN C27 GENSETS

Usage:

REBE2036-01

Show/hide table

11Jul2007

(Revised 19Sep2007)

U-317

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR JACKET WATER HEATER CONTACTOR WIRING AND LOGIC ON CERTAIN C27 GENSETS
1383 7400 1400		PI31302

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31302" 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 "PI31302" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the July 11, 2007 Service Letter. Changes have been made to Affected Product.

Show/hide table

COMPLETION DATE	TERMINATION DATE
31Jan2008	31Jul2008

PROBLEM

Show/hide table

The contactor wiring and logic needs to be inspected and reworked on certain C27 Gensets covered in this program. The current contactor wiring and logic may not operate the Jacket Water Heater.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
*****Group 1*****
C27	DWB00102-00103, 105, 110, 114-115, 117-120, 122

Show/hide table

*****Group 2*****
C27	DWB00111-00112, 582

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
*****Group 1*****
This Group does not have any parts.
*****Group 2*****
1	2110640	SPRING-RELAY
1	2236470	RELAY
1	2521731	MODULE-DIODE
1	2521732	BASE-RELAY

ACTION REQUIRED

Show/hide table

Refer to the attached Rework Procedure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

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

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 0.5-hour job for Group 1

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 2

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.

Show/hide table

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR JACKET WATER HEATER CONTACTOR WIRING AND LOGIC

MODELS INVOLVED - Certain C27 Gensets

Dear Caterpillar Product Owner:

The contactor wiring and logic needs to be inspected and reworked on certain C27 covered in the program. The existing contactor wiring and logic will not operate the Jacket Water Heater.

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 11Jul2007 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 11Jul2007 Service Letter

Rework Procedure

Group Number 2

1. Check the Genset model is on the service program. Only continue if
the serial No. is on the order.

2. Isolate Genset before commencing any work on the unit; activate emergency stop, isolate auxiliary voltage supply, disconnect battery cables, and open breaker. Ensure health and safety requirements are adhered to at all times.

3. Verify the following wiring:

131 in main terminal strip lands on RO6-NO
132 in main terminal strip lands on RO6-C and Aux(-)

Note: If these wires are not properly landed already, they may be landed on terminals very near the correct terminals.

4. Collect the following P/Ns to add to the upper DIN rail on AC/DC panel:

211-0640
223-6470
252-1731
252-1732

5. Make the following connections to change from the Image 1.1.1 state to the Image 1.1.2 state:

Image1.1.1

Image1.1.2

5.1. Move the end block near the existing contactor to the right.
5.2. Disconnect wire 137 from terminal A1 of the existing contactor.
5.3. Disconnect wire 131 from terminal A2 of the existing contactor.
5.4. Place a jumper between terminals 11 and A1 of the new contactor.
5.5. Add a jumper to terminal 12 of the new contactor (to be connected to A1 of the existing contactor in Step 5.9.
5.6. Connect wire 137 to A1 of the new contactor.
5.7. Connect wire 131 to A2 of the new contactor.
5.8. Install contactor onto DIN rail.
5.9. Connect the jumper wire connected to terminal 12 of the new contactor in step 5.5 to terminal A1 of the existing contactor.
5.10. Add a jumper from Aux(-) on the lower terminal block of the marshalling box to terminal A2 of the old contactor.
5.11. Tighten end block.

Note: The contactor on the AC/DC options panel should "click" upon applying 24VDC power to the genset.

6. Run a function test on the Jacket Water Heater system.

Group Number 1

1. Check the Genset model is on the service program. Only continue if
the serial No. is on the order.

2. Isolate Genset before commencing any work on the unit; activate emergency stop, isolate auxiliary voltage supply, disconnect battery cables, and open breaker. Ensure health and safety requirements are adhered to at all times.

3. Verify the following wiring:

131 in main terminal strip lands on DO-1
132 in main terminal strip lands on RO6-C and Aux(-)

Note: If these wires are not properly landed already, they may be landed on terminals very near the correct terminals.

4. Reset E-stop and Power up the EMCP with 24VDC.

5. Set the Digital Output 1 to Active Low as follows:

In the EMCP Main Menu
Select Configure
Select Setpoints
Select I/O
Select Digital Outputs
Select Digital Output #1
Change active state from High to Low

Note: The contactor on the AC/DC options panel should "click" upon changing state of Digital Output #1.

6. Run a function test on the Jacket water heater system.