PRODUCT IMPROVEMENT PROGRAM FOR REWIRING CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B, AND 3516C GENSETS WITH EMCP 3.X Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWIRING CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B, AND 3516C GENSETS WITH EMCP 3.X

Usage:

REBE3275-00

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29Aug2008

U-451

A-368

D-373

O-411

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWIRING CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B, AND 3516C GENSETS WITH EMCP 3.X
7451 4490 1907		PI31551

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31551" 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 "PI31551" 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
28Feb2009	31Aug2009

PROBLEM

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The current wiring configuration needs to be reworked on certain 3508, 3508B, 3512, 3512B, 3516, 3516B, and 3516C gensets with EMCP 3.x. The existing wiring configuration can cause excessive electrical noise resulting in a failure to start the unit.

AFFECTED PRODUCT

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Model	Identification Number
3508	ZAB00130-00135, 138-139, 145-157
3508B	ZAD00190, 233-234, 238, 240-243, 246-249, 256, 263-266, 270, 272-276, 281-295, 299-301, 304, 306-352
3512	SBG00153, 175-248, 250-267, 269-289, 291-294, 297, 299-368, 370-382, 384, 386 ZAF00211, 244-245, 261-264, 266-275, 277, 279-282, 284, 287-291, 293, 296, 299-302, 306-307, 310-311, 313-314, 317-322, 325-327, 331-332, 335, 343, 346-347, 350-353, 355-401
3512B	ZAH00327, 342-348, 351-359, 365-369, 372-378, 380-395, 401-403, 406, 408, 410-414, 417-427, 430-436, 438-439, 441-444, 447-449, 452-455, 457-461, 463-470, 472, 474-481, 484-485, 488-497, 499-504, 507-508, 510, 512-516, 518, 520-528, 534-543, 546-548, 553-555, 564-566, 569-573, 575-579, 587-588, 592-664 ZAJ00129-00133, 136, 138-139, 144-145, 147-149, 151, 153, 155-159, 163-180
3516	ZAL00172-00173, 177, 194, 197, 199-203, 205-209, 211, 213-214, 216-217, 222, 226-227, 231-234, 240-242, 254-256, 269-272, 274, 281-296
3516B	PBR00224-00282, 284-510 ZAP00372-00387, 389-400, 402-403, 406-408, 410-411, 414-417, 419-447, 449-460, 462-465, 468-469, 471-476, 478-484, 487-502, 504-517, 519-562, 564-576, 579-581, 586-593, 595-597, 599-601, 603-604, 608-612, 614, 620-630, 632-649, 653-654, 656-658, 660, 664-665, 667-668, 671-674, 677-688, 690-695, 697-776 ZAR00174-00179, 181-184, 187-204, 208, 210, 212-214, 216, 219-226, 228, 230, 232-233, 235-247, 249, 252-255, 258-267, 269-271, 273-278, 283, 289-339
3516C	SBJ00203-00346, 348, 350-399, 401-508, 511-516 SBK00182, 188-251, 253-276, 278, 280-400

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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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached 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%

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NOTE: This is a 0.5-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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWIRING CERTAIN 3508, 3508B, 3512, 3512B, 3516, 3516B, AND 3516C GENSETS WITH EMCP 3.X

MODELS INVOLVED - 3508, 3508B, 3512, 3512B, 3516, 3516B, and 3516C GENSETS

Dear Caterpillar Product Owner:

The wiring configuration needs to be reworked for the engine speed signal on the products listed below. The existing wiring configuration can cause electrical noise interferring with starting the unit. 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 29Aug2008 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 29Aug2008 Service Letter

Rework Procedure

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Verify that the crank terminate speed is set to 400rpm in the EMCP 3.x. This service letter will cover three possible situations that need to be accounted for when rewiring the Magnetic Pick-Up (MPU) cable.

Situation 1 - Servicing a panel as shipped by the factory.

If the factory installed MPU speed signal cable is being used (as shown in image 1.1.1), and no modifications have been made, move the shield wire (#838) from the ground location (2) on the terminal block to the battery (-)location (1) on the terminal block.

Image1.1.1

Situation 2 - Servicing a panel that was modified using prior direction from the DSN (Dealer Solution Network).

In some cases a new MPU cable (1) has been connected from the MPU to the EMCP 3.x as a result of an earlier Interim Corrective Action (ICA). Refer to Image 1.2.1

NOTE: This procedure will not be required unless the ICA was performed.

On the EMCP end of the MPU cable, use an insulated wire to extend the MPU cable shield to terminate on the battery (-) location (1) of the terminal strip in the AC\DC box. Refer to Image 1.2.2

Image1.2.1

Image1.2.2

Situation 3 - Servicing a panel with a Remote Wall Mount EMCP 3.x. Image 1.3.1.

Remove the MPU shield wire #838 from terminal location #2 (1) in the AC\DC box and connect to terminal location #2A (2). Refer to Image 1.3.2.

If the MPU shield wire is not long enough, it may be necessary to relocate a longer wire from one 2A position to another 2A position.