PRODUCT IMPROVEMENT PROGRAM FOR EMCP3 CONTROLS FUEL RELAY CIRCUIT ON CERTAIN 3406C, 3456, 3412, C15, C18, AND C-18 GENSET PACKAGES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR EMCP3 CONTROLS FUEL RELAY CIRCUIT ON CERTAIN 3406C, 3456, 3412, C15, C18, AND C-18 GENSET PACKAGES

Usage:

REBE4298-00

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27Oct2008

U-542

A-448

D-458

O-496

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR EMCP3 CONTROLS FUEL RELAY CIRCUIT ON CERTAIN 3406C, 3456, 3412, C15, C18, AND C-18 GENSET PACKAGES
4466 4490		PI31570

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31570" 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 "PI31570" 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
30Apr2009	31Oct2009

PROBLEM

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The existing 208-9270 Transorb can cause damage to relay 2 in the EMCP3 controller on certain 3406C, 3456, 3412, C15, C18, and C-18 genset packages..

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3406C	C2G01526, 1528, 1530, 1536, 1538, 1541, 1543-1546, 1550, 1552-1554, 1566, 1568, 1570, 1572-1573, 1575-1584, 1586-1588, 1591-1593, 1597-1598, 1603-1605, 1607, 1609-1615, 1617-1618, 1621-1622, 2355, 3142-3143, 3151, 3156, 3192, 3196, 3198, 3205, 3212, 3237, 3240, 3242, 3257-3258, 3266-3268, 3273-3274, 3285, 3290-3291, 3312, 3344, 3346, 3349-3350, 3359, 3362, 3366, 3374, 3376, 3385, 3388-3389, 3422-3423, 3425-3427, 3433-3434, 3450, 3457, 3461-3462, 3467, 3471, 3485, 3496, 3502-3503, 3507, 3509, 3512-3513, 3517, 3519-3520, 3522, 3551-3552, 3555-3556, 3558, 3568, 3574, 3585, 3628-3630, 3634, 3639, 3641, 3643, 3649-3651, 3654-3656, 3658-3659, 3667, 3669-3670, 3680, 3684-3685, 3690-3692, 3707-3709, 3722, 3727, 3737-3738, 3741, 3750, 3754, 3756, 3761, 3771, 3781, 3785-3786, 3790-3792, 3795, 3814-3815, 3819, 3830, 3833-3835, 3837, 3839, 3842, 3860, 3866, 3879-3880, 3885, 3895-3896, 3916-3918, 3939, 3948, 3951-3952, 3955, 3965-3969, 3972, 3974, 4002, 4017-4018, 4073, 4079, 4090, 4093, 4095, 4103, 4120-4121, 4123, 4128, 4132, 4134, 4138, 4142, 4147, 4151, 4155, 4163, 4168, 4171-4172, 4178-4181, 4183, 4187-4188, 4191-4194, 4200-4204, 4207, 4210, 4212, 4216, 4219-4221, 4223, 4227, 4229-4231, 4239, 4245-4246, 4248-4250, 4252-4253, 4258, 4260, 4265, 4267, 4273-4277, 4292-4298, 4301, 4303-4305, 4311-4312, 4314-4315, 4317-4318, 4324, 4326, 4328, 4331-4332, 4334, 4340, 4342-4349, 4351-4355, 4357-4360, 4362, 4364-4374, 4376-4383, 4385-4388, 4390-4392, 4394-4410, 4412-4425, 4427, 4429, 4432-4433, 4436-4446, 4448-4449, 4453-4454, 4459-4461, 4464, 4466, 4468-4470, 4472-4473, 4478-4479, 4481-4486, 4489-4492, 4494-4504, 4506-4508, 4512-4520, 4522, 4524, 4526-4529, 4533-4536, 4540, 4542-4552, 4554-4555, 4557, 4559, 4561-4562, 4564, 4567-4568, 4570-4574, 4576-4581, 4584-4586, 4590, 4592-4593, 4595-4596, 4602-4604, 4606-4621, 4623-4625, 4627-4628, 4630-4631, 4635, 4638, 4640, 4643-4645, 4648-4649, 4656, 4660, 4662-4663, 4666-4668, 4672, 4675, 4677-4680, 4684-4685, 4690, 4699, 4704, 4708-4709, 4715, 4728, 4733, 4737-4738, 4747, 4749, 4760-4761, 4766, 4768-4769, 4774-4775, 4780-4783, 4786-4791, 4793, 4795-4796, 4798-4800, 4802-4803, 4805-4811, 4813-4816, 4824-4826, 4828-4833, 4835-4854, 4856-4868, 4870-4884, 4886-4890, 4892-4893, 4895, 4898-4907, 4909-4910, 4914, 4916-5235, 5237-5272, 5274, 5276, 5278-5279, 5281-5288, 5290, 5292 C2Y00150-00152, 155-165, 168-169, 172-173, 180, 184-193, 195-196, 198-199, 201-203, 205-206, 208, 214, 217-219, 221, 223-229, 231-233, 239, 241-242, 245-246, 248-249, 351-352, 355-357, 360 C8G00564, 582-585, 595-597, 609-621
3456	C1G01608
C-18	G4C00706, 767, 890, 943, 1016, 1019, 1022-1023, 1091, 1114, 1116, 1118, 1156, 1170, 1175, 1180, 1188, 1192, 1206, 1210, 1212, 1228, 1234, 1259-1260, 1303, 1329, 1346-1349, 1357, 1374-1375, 1380-1382, 1386, 1388-1389, 1393-1394, 1399, 1402, 1406, 1411, 1414, 1420, 1436, 1444, 1459, 1479, 1484-1485, 1496, 1506, 1515, 1528, 1535, 1545, 1551, 1597, 1612, 1618, 1621, 1625, 1648-1649, 1651, 1659, 1662, 1676, 1680, 1688, 1690, 1699-1701, 1704, 1715, 1718, 1724-1725, 1730, 1740, 1745, 1751, 1754, 1772, 1777, 1782, 1784-1786, 1790, 1799, 1806-1807, 1811-1812, 1816-1818, 1824, 1830, 1835-1836, 1839, 1843-1844, 1852, 1861, 1865, 1870, 1874-1877, 1880, 1882, 1884, 1894, 1898, 1900, 1908-1910, 1917, 1924-1925, 1927-1928, 1934, 1945-1947, 1949-1950, 1956, 1960, 1962-1963, 1969-1970, 1974, 1980, 1991-1993, 1997, 1999, 2004, 2006, 2008, 2015, 2017, 2020-2022, 2025, 2035, 2039, 2041-2042, 2047, 2054, 2061, 2063, 2073-2074, 2077, 2099, 2103, 2105, 2107, 2109, 2115, 2117-2118, 2121-2124, 2126-2129, 2131, 2133-2135, 2137, 2139-2142, 2144-2145, 2147, 2150-2151, 2154-2155, 2158, 2160, 2163-2164, 2166, 2168, 2171, 2175-2179, 2186-2187, 2190, 2192-2193, 2197, 2199, 2201, 2203, 2207, 2213-2214, 2222, 2225, 2227-2229, 2231, 2233, 2236-2238, 2240, 2244, 2246-2247, 2249-2251, 2253, 2256, 2262, 2264-2266, 2268-2278, 2280, 2286-2287, 2289-2290, 2293, 2295, 2297, 2299, 2301, 2304, 2306-2307, 2310-2311, 2314-2319, 2321, 2325-2326, 2331, 2333-2337, 2339-2342, 2346-2362, 2364-2365, 2369, 2373-2376, 2378-2380, 2384-2395, 2397-2408, 2411-2419, 2424-2425, 2427-2428, 2430-2434, 2436, 2438, 2440-2442, 2444, 2446-2448, 2454, 2456-2459, 2461-2462, 2466, 2468, 2470-2472, 2474-2480, 2482-2488, 2490-2495, 2497-2499, 2501-2514, 2516-2524, 2526-2536, 2538, 2540-2547, 2549-2561, 2563-2564, 2566-2577, 2579-2590, 2592-2599, 2601, 2603-2610, 2612-2618, 2620-2629, 2631-2642, 2644-2649, 2651-2653, 2655-2656, 2658-2670, 2672-2678, 2680-2693, 2696-2775, 2777-2784, 2786-2791, 2793-2824, 2826-2855, 2857-2895, 2897-2899, 3000-3055, 3057-3098, 3100-3120, 3122-3127, 3129-3154, 3156-3168, 3170-3179, 3181-3213, 3215-3225, 3227-3231, 3233-3234, 3236, 3238-3240, 3242-3249, 3252-3269, 3271-3486, 3488-3502, 3504-3505, 3507-3511
C15	C5L00123, 126-127, 140, 147-148, 153, 155-156, 158, 161, 167-169, 174-175, 177-178, 181-182, 187-188, 191-192, 194, 196, 199-201, 204, 210, 212, 227, 231, 233, 238-241, 244-246, 248, 250, 261-263, 266, 269-270, 273, 300-303, 305-309, 312-315, 318-345, 347, 349-350, 453-454, 456-464, 466-467, 469, 473-484, 486-489, 491-495, 497-501, 503-509, 513-516, 518-526, 529-531, 534, 536, 538-542, 544, 546-550, 554-555, 558, 560-561, 564-565, 567-570, 572, 574-577, 579, 581-592, 594-602, 604, 606-613, 615, 617, 620, 622, 625-626, 629-630, 633-636, 639-640, 642-645, 647, 650, 652-653, 655-659, 661, 665-674, 677-682, 686, 688-692, 694-698, 700-706, 708, 710-715, 717-722, 724-728, 730-750, 752, 755-757, 759-763, 765-770, 772-777, 779, 782-784, 787, 790-791, 793-800, 802-805, 807-810, 813-820, 822, 824-833, 835-844, 846-847, 850-867, 869-881, 884-886, 888-891, 893-902, 904-913, 915-936, 938-956, 958-1017, 1019-1025, 1029-1051, 1053-1102, 1104-1165, 1167-1363, 1365-1617, 1619-1710, 1712-1729, 1731-1734, 1736-1765, 1767-1774, 1776-1779, 1781-1792, 1794-1825, 1827-1833, 1835-1842, 1846-1849, 1851, 1853 CYY00100, 102-155 STG00100-00104, 106, 108-111, 117-119
C18	C6C00281, 286, 306, 308, 311, 318, 323-326, 349-350, 354-367, 383-392, 422, 431, 444-447, 454-455, 457, 461-462, 472-477, 482-486, 488-493 DKE00300-00301, 311, 512, 514

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*******Group 2*******

3412C

4BZ08619, 8628, 8667, 8676, 8708, 8710, 8734-8735, 8738, 8746, 8751, 8756, 8772, 8821, 8824, 8826, 8828, 8830, 8843, 8856, 8860, 8866, 8874, 8882, 8884-8885, 8900, 8902-8903, 8909, 8911, 8915, 8918-8919, 8942, 8944-8948, 8950, 8952, 8956, 8976, 8983, 8985-8986, 8993, 9021, 9023, 9026, 9041-9043, 9045, 9047-9048, 9053-9059, 9074-9075, 9080, 9082, 9085-9086, 9089, 9107-9108, 9111-9113, 9115, 9117, 9124, 9128-9129, 9135, 9149-9150, 9154-9157, 9159, 9161-9162, 9165, 9169-9170, 9176-9182, 9185-9190, 9292, 9294, 9299, 9302-9303, 9306, 9309, 9316, 9326-9329, 9331, 9333, 9338-9341, 9345, 9347, 9349, 9351, 9354-9355, 9358-9360, 9363, 9366-9367, 9369, 9372-9373, 9378, 9381, 9384, 9389-9396, 9401, 9408, 9410-9412, 9414, 9417, 9419, 9421, 9426, 9428-9431, 9433, 9435-9440, 9442, 9444-9446, 9454-9458, 9461-9463, 9465-9471, 9473-9474, 9476, 9480-9481, 9484-9487, 9489-9491, 9493-9494, 9496-9502, 9504-9516, 9518-9519, 9521-9538, 9540-9547, 9552-9553, 9555, 9557-9575, 9577-9591, 9593-9596, 9604-9605, 9607-9616, 9618-9619, 9624, 9630-9633, 9635-9641, 9643-9662, 9664-9669, 9672-9675, 9678-9695, 9697, 9699-9705, 9707-9711, 9717-9723, 9725-9731, 9733-9738, 9740, 9743-9744, 9746-9748, 9750-9751, 9753-9754, 9756, 9763-9766, 9768, 9770-9772, 9774-9775, 9777, 9779-9781, 9786, 9788-9792, 9794-9811, 9813-9814, 9816-9818, 9821-9824, 9826, 9829-9835, 9837-9840, 9842-9847, 9849-9850, 9852, 9855-9856, 9858, 9860, 9862-9864, 9866-9867, 9872-9873, 9876-9878, 9880, 9884-9887, 9890, 9893, 9895-9897, 9899-9900, 9902-9903, 9905-9906, 9909, 9914-9915, 9917-9922, 9924-9927, 9930-9932, 9935-9936, 9942, 9944, 9946-9951, 9956-9957, 9959, 9963, 9965-9966, 9968-9974, 9979, 9981, 9983, 9987-9993, 9996-10000, 10002-10005, 10007-10009, 10011-10014, 10016-10017, 10019-10032, 10035-10039, 10041-10043, 10045-10050, 10052-10058, 10060-10075, 10077-10081, 10083-10094, 10096-10098, 10101-10109, 10111-10112, 10114-10120, 10124-10125, 10127-10130, 10132, 10136-10143, 10145-10147, 10149-10150, 10153, 10155-10159, 10161-10165, 10167-10172, 10174-10175, 10177-10178, 10181, 10183-10189, 10192-10197, 10200-10201, 10203-10206, 10208-10213, 10215-10223, 10225-10227, 10231, 10233-10239, 10242-10244, 10246, 10248, 10250-10252, 10256-10257, 10259, 10261-10266, 10269, 10271, 10273, 10285, 10287, 10291, 10295

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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The 208-9270 Transorb needs to be removed.

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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

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

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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 0.5-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.

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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 EMCP3 CONTROLS FUEL RELAY CIRCUIT ON CERTAIN 3406C, 3456, 3412, C15. C18, AND C-18 GENSET PACKAGES

MODELS INVOLVED - 3406C, 3456, 3412, C15, C18, AND C-18 GENSET PACKAGES

Dear Caterpillar Product Owner:

The 208-9270 Transorb needs to be removed on certain 3406C, 3456, 3412, C15, C18, and C-18 genset packages. The existing 208-9270 Transorb can cause damage to relay 2 in the EMCP3 controller. 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 27Oct2008 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 27Oct2008 Service Letter

Rework Procedure

Group Number 1

Refer to appropriate service manual as necessary.

1. Isolate Genset before commencing any work on the unit, open Genset breaker, activate Emergency Stop, disconnect the auxiliary power supply for battery charger and heaters, and disconnect battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

2. Open control panel door and locate CR relay and remove the 208-9270 Transorb. Refer to Image 1.1.1 and Image 1.1.2. No replacement diode is required.

Image1.1.1

Image1.1.2

3. Clear generator area, reconnect batteries, and release emergency stop.

4. Run functional No Load test on Genset.

Group Number 2

Refer to appropriate service manual as necessary.

1. Isolate Genset before commencing any work on the unit, open Genset breaker, activate Emergency Stop, disconnect the auxiliary power supply for battery charger and heaters, and disconnect battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

2. Open control panel door and locate CR relay and remove the 208-9270 diode see Image 2.1.1 and Image 2.1.2. No replacement diode is required.