PRODUCT SUPPORT PROGRAM FOR REWORKING XQ MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING XQ MODULES

Usage:

REBE2264-02

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27Jul2007

(Revised 18Apr2008)

B420
H160
H335
H370
H374

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING XQ MODULES
7274 1250 1408 7620 1051 1406		PS42476

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NOTE:

This Program must 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 "PS42476" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 27Jul2007 Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

31Jul2009

PROBLEM

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The existing XQ Module did not meet Dealer satisfaction.

AFFECTED PRODUCT

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Model	Identification Number
PM3508B	BLM00253-00262, 264-269
PM3512B	BNR00318-00327, 343, 345

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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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%
0-9999 hrs, 0-999 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 125.0-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.

Rework Procedure

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The following repairs, wiring, and programming changes need to be
made. All parts mentioned within this rework procedure have been provided by either Enercon, ISO, or Tramont.

1. Leaks were found at some of the threaded joints leading out of the
fuel tank. Use 5P-3413 Sealant or an equivalent thread sealant for
the fuel tank fittings.

2. Replace the 249-2924 Fuel Line Fitting with a 47270 pipe thread
fitting supplied by the power module manufacturer. This is a 3/4 inch
pipe thread with a 30 degree flare.

3. Weather stripping was being used on the roof hatch to prevent
leaking. Replace the existing roof hatch weather stripping with a suitable seal.

4. Check/Re-weld Cable Access Panel. Current cable access panel
should have 20+ spot welds.

5. Current fuel tanks were sent without the proper UL plates. Attach
the proper UL plates provided by the fuel tank supplier.

6. Reorient the Air Cleaners so that the lid retaining clip does not
hit the sound attenuation of the enclosure.

7. Replace the current fuel supply line for the fuel tank with 209-
0786 Hose As. Parts to be supplied by the power module fuel tank
supplier.

8. Re-orient the battery rack in order to achieve better personnel
access (dealer to use discretion based on best ergonomic\safe
location for battery placement).

9. Place proper battery cable terminals on appropriate battery posts.

10. Per prior verbal agreement and drawing mark-up on wiring print
300-7351, rewire the battery charger connection at the keyswitch.

11. Ensure that fuel supply pipe from the Primary Fuel filter is
properly supported by p-clip.

12. Program EMCP3 cool down parameter to "0" cooldown time.

13. Flash EMCP3 to latest software revision.

14. Refer to drawing #300-7356. Ensure that the speed control
wires (PWM) are connected properly within the switchgear and the
generator control panel.

15. Program both the CDVR and EMCP3 such that the Switchgear becomes
the primary shutdown on faults.

16. Program the EMCP3 such that "Custom Event" is "SWGR E-stop Alarm".

17. Rewire the Low Oil Make-up/Low Engine Oil and Low Coolant/Low
After Cooler Alarm referenced in Cat drawing #300-7351 (are not) in
series. Also program EMCP3 for two separate inputs.

18. As per prior verbal agreement and drawing mark-up on wiring print
300-7351 re-install wire A2 coil on block heaters.

19. Original wire labels were not installed to call out the wire
numbers, install wire labels on wiring from thermostat to circulating
pump.

20. Original wire labels were not installed to call out the wire
numbers, install wire labels on interconnect wiring to switchgear.

21. Wire ferrules were not used during the initial installation,
please install wire ferrules for interconnecting wires.

22. Readjust door latch on power module (reference Cat drawing 156-
9152).

The following programming and electrical wiring changes need to be
made. All parts associated with this rework have been provided by ISO.

Image1.1.1

1. Reorient the current battery charger (dealer to use discretion
based on best ergonomic/safe location for battery placement).

NOTE: Each module will be getting the following switchgear updates as
per ISO drawing sets 293-2472 (for 3508 packages) and 293-2473 (for
3512 packages).

2. Add the Auto-Start Relay, wiring and parts.

3. Add Customer Alarm Contacts, wiring and parts.

Install the new programming software (program updated and provided by
ISO) to cover the following issues:

4. Be able to display the "Not-in-Auto Alarm".

5. Fuel System Alarm, Rupture Basin Alarm & Critical Low Fuel
Shutdown

6. Fail to Start/Overcrank

7. EMCP3 Estop

8. Change from metric to English

9. Total Burn/Consumption