PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING THE ALTERNATOR/START RELAY CIRCUIT BREAKER, START RELAY, AND INLET AIR HEATER CIRCUIT BREAKER ON CERTAIN C7 AND C9 MARINE ENGINES
Usage:
REBE3046-00
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| 20Dec2007 |
U-676
A-546
D-549
TM-22
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| Priority | PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING THE ALTERNATOR/START RELAY CIRCUIT BREAKER, START RELAY, AND INLET AIR HEATER CIRCUIT BREAKER ON CERTAIN C7 AND C9 MARINE ENGINES |
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| 1420 1408 1000 7499 | PI31419 |
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| NOTE: | This Program must be administered as soon as possible. When reporting the repair, use "PI31419" 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 "PI31419" 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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| 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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COMPLETION DATE |
TERMINATION DATE |
| 30Jun2008 | 31Dec2008 |
PROBLEM
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| The alternator/start relay circuit breaker, start relay, and inlet air heater circuit breaker needs to be inpected and, if necessary, replaced on certain C7 and C9 Marine Engines. Engines with 12-volt starting systems that have an incorrect alternator/start relay circuit breaker may develop an open condition in the starting circuit during normal starting operation. Engines with 24-volt starting systems that have an incorrect alternator/start relay circuit breaker will damage the start relay. Engines with improper inlet air heater circuit breaker may not develop the necessary power needed to start the engine for cold weather applications. Engines with an incorrectly installed start relay will damage the start coil. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| C7 | M7A00100-00106, 108-115 M7G00101-00102, 104-118 |
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| *******Group 2******* | |
| C9 | X9Y00097-00099, 101, 103-138 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 1 | 3E0075 | SWITCH AS-MAGC |
| 1 | 3E7278 | SWITCH AS-MAGC |
| 1 | 1712211 | BREAKER AS-CKT |
| 1 | 1712213 | BREAKER AS-CKT |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer. | ||
| *******Group 2******* | ||
| 1 | 3E0075 | SWITCH AS-MAGC |
| 1 | 3E7278 | SWITCH AS-MAGC |
| 1 | 1712211 | BREAKER AS-CKT |
| 1 | 1712213 | BREAKER AS-CKT |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer. | ||
ACTION REQUIRED
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| Refer to the attached Rework Procedure. |
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OWNER NOTIFICATION
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| U.S. and Canadian owners will receive the attached Owner Notification. |
SERVICE CLAIM ALLOWANCES
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| *******Group 1******* | |||||
| NOTE: This is a 1.0-hour job for Group 1 | |||||
| Please note the sister engine serial number installed in the boat in the claim story as only one trip will be covered for a pair of engines in a boat. |
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| *******Group 2******* | |||||
| NOTE: This is a 1.0-hour job for Group 2 | |||||
| Please note the sister engine serial number installed in the boat in the claim story as only one trip will be covered for a pair of engines in a boat. |
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. |
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| COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS XYZ Corporation 3240 Arrow Drive Anywhere, YZ 99999 PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND, IF NECESSARY, REPLACING THE ALTERNATOR/START RELAY CIRCUIT BREAKER, START RELAY, AND INLET AIR HEATER CIRCUIT BREAKER ON CERTAIN C7 AND C9 MARINE ENGINES. MODELS INVOLVED - C7 and C9 Marine Engines Dear Caterpillar Product Owner: The alternator/start relay circuit breaker, start relay, and inlet air heater circuit breaker need to be inspected and, if necessary, replaced on the products listed below. Engines with 12-volt starting systems that have an incorrect alternator/start relay circuit breaker may develop an open condition in the starting circuit during normal starting operation. Engines with 24-volt starting systems that have an incorrect alternator/start relay circuit breaker will damage the start relay. Engines with improper inlet air heater circuit breaker may not develop the necessary power needed to start the engine for cold weather applications. Engines with an incorrectly installed start relay may damage the start coil. 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 20Dec2007 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 20Dec2007 Service Letter |
| Group Number 1 |
| The correct circuit breaker and relay part numbers are dependent on the system voltage of the engine. Below is the compatibility for the two circuit breakers and start relay: Alternator/Start Relay Circuit Breaker Part Numbers i. For a 24V system, 90A circuit breaker: 171-2211 ii. For a 12V system, 135A circuit breaker: 171-2213 Air Inlet Heater Circuit Breaker Part Number i. For a 12V or a 24V system, 135A circuit breaker: 171-2213 Start Relay i. For a 12V system: 3E7278 ii. For a 24V system: 3E0075 Please use the following rework procedure to inspect the circuit breakers and start relay to ensure that the correct part number was installed and replace them if necessary. 1. Ensure the engine is not connected to power. Isolate the engine before commencing any work on the unit. Disconnect battery cables. Ensure health and safety requirements are adhered to at all times. 2. Visually verify air inlet heater circuit breaker button displays 135, which represents the amperage of the circuit breaker (Part # 171-2213). Location shown in Image 1.1.1. To change remove two mounting bolts and switch out part. |
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| Image1.1.1 |
| 3. Locate the alternator/start relay circuit breaker. Refer to image 1.2.1. For 12-volt starting systems, visually verify starting motor circuit breaker located in the bracket assembly is stamped 135. For 24-volt systems, visually verify starting motor circuit breaker located in the bracket assembly is stamped 90. A 12-volt system shown in image 1.2.2. |
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| Image1.2.1 |
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| Image1.2.2 |
| 4. Locate the start relay next the starting motor circuit breaker on the bracket assembly. Refer to image 1.3.1 |
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| Image1.3.1 |
| 5. To check the start relay remove the bracket assembly bolts (Image 1.4.1). Remove both start relay nuts (Image 1.4.2). Angle bracket assembly away from engine and separate start relay from bracket assembly. The start relay part number is on a sticker on the housing (Image 1.4.3). A 12-volt start system shown in Image 1.4.3 uses a start relay part number 3E7278 and a 24-volt start system uses a start relay part number 3E0075. |
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| Image1.4.1 |
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| Image1.4.2 |
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| Image1.4.3 |
| 6. Ensure that the correct start relay part number is installed. If not, replace with the correct start relay. 7. If the system has already been energized, the start relay coil will need to be diagnostic checked and replaced if necessary. 8. Before reinstalling the breakers and relay ensure the wiring is organized so that no wire comes into contact with block surfaces. Contact with block surfaces will cause interference and may result in harness failure. To change the start relay disconnect the two posts. Replace part and reconnect. To change the alternator/start relay circuit breaker disconnect the wiring and remove the two mounting bolts. Change the circuit breaker and reconnect. Image 1.5.1 |
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| Image1.5.1 |
| Group Number 2 |
| The correct circuit breaker and relay part numbers are dependent on the system voltage of the engine. Below is the compatibility for the two circuit breakers and start relay: Alternator/Start Relay Circuit Breaker Part Numbers i. For a 24V system, 90A circuit breaker: 171-2211 ii. For a 12V system, 135A circuit breaker: 171-2213 Air Inlet Heater Circuit Breaker Part Number i. For a 12V or a 24V system, 135A circuit breaker: 171-2213 Start Relay i. For a 12V system: 3E7278 ii. For a 24V system: 3E0075 Please use the following rework procedure to inspect the circuit breakers and start relay to ensure that the correct part number was installed and replace them if necessary. 1. Ensure the engine is not connected to power. Isolate the engine before commencing any work on the unit. Disconnect battery cables. Ensure health and safety requirements are adhered to at all times. 2. Visually verify air inlet heater circuit breaker button displays 135 which represents the amperage of the circuit breaker (Part # 171-2213). Location shown in Image 2.1.1. To change remove two mounting bolts and switch out part. |
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| Image2.1.1 |
| 3. Locate the alternator/starting motor circuit breaker. Refer to image 2.2.1. For 12-volt starting systems, visually verify starting motor circuit breaker located in the bracket assembly is stamped 135. For 24-volt starting systems, visually verify starting motor circuit breaker located in the bracket assembly is stamped 90. Refer to image 2.2.2 |
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| Image2.2.1 |
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| Image2.2.2 |
| 4. Locate the start relay next the starting motor circuit breaker on the bracket assembly. Refer to image 2.3.1 |
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| Image2.3.1 |
| 5. To check the start relay remove the bracket assembly bolts (Image 2.4.1). Remove both start relay nuts (Image 2.4.2). Angle bracket assembly away from engine and separate start relay from bracket assembly. The start relay part number is stamped on the housing (12 volt system shown in image 2.4.3 & 2.4.4). A 12-volt start system uses a start relay part number 3E7278 and a 24-volt start system uses a start relay part number 3E0075. |
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| Image2.4.1 |
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| Image2.4.2 |
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| Image2.4.3 |
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| Image2.4.4 |
| 6. Ensure that the correct start relay part number is installed. If not, replace with the correct start relay. 7. If the system has already been energized, the start relay coil will need to be diagnostic checked and replaced if necessary. 8. Before reinstalling the breakers and relay, ensure the wiring is organized so that no wire comes into contact with block surfaces. Contact with block surfaces will cause interference and may result in harness failure. To change the start relay disconnect the two posts. Replace part and reconnect. To change the alternator/start relay circuit breaker disconnect the wiring and remove the two mounting bolts. Change the circuit breaker and reconnect. Images 2.5.1 and 2.5.2 |
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| Image2.5.1 |
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| Image2.5.2 |
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