PRODUCT IMPROVEMENT PROGRAM FOR ISOLATING A 3E-5239 ECM POWER SHUTOFF RELAY ON CERTAIN C27, C32, AND PMC32 GENSETS AND FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE AND REWIRING THE MAGNETIC PICK-UP CABLE ON CERTAIN C32 GENSETS WITH EMCP 3.X Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR ISOLATING A 3E-5239 ECM POWER SHUTOFF RELAY ON CERTAIN C27, C32, AND PMC32 GENSETS AND FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE AND REWIRING THE MAGNETIC PICK-UP CABLE ON CERTAIN C32 GENSETS WITH EMCP 3.X

Usage:

REBE4440-02

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24Nov2008

(Revised 23Oct2009)

U-599

A-496

D-511

O-550

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR ISOLATING A 3E-5239 ECM POWER SHUTOFF RELAY ON CERTAIN C27, C32, AND PMC32 GENSETS AND FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE AND REWIRING THE MAGNETIC PICK-UP CABLE ON CERTAIN C32 GENSETS WITH EMCP 3.X
1920 7451 4490 4493 1901		PI31586

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31586" 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 "PI31586" 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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NOTE:	This Revised Service Letter replaces the 24Nov2008 (Revised 14May2009) Service Letter. Changes have been made to Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31May2009	30Nov2009

PROBLEM

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The 3E-5239 ECM power shutoff relay on certain C27, C32, and PMC32 gensets will fail due to excessive vibration levels resulting in an unexpected engine shutdown or a failure to start. Under certain conditions, engine ECM software may cause the engine to fail to start during a start cycle. In addition, a wiring configuration of the Magnetic Pick-Up (MPU) cable, on certain C32 gensets with EMCP 3.x, may cause excessive electrical noise resulting in a failure to start.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C27	DWB00102-01155, 1158-1165, 1167-1173, 1175-1177, 1181-1182, 1184-1185, 1188

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*****Group 2*****
PMC32	MED00100-00130, 132-180

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*****Group 3*****
C32	SXC00300-00593, 595-621, 627-658, 660-661, 665-676, 678-1963

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*******Group 4*******

C32

SXC02268-02694, 2714, 2757-2760, 2769-2774, 2780-2792, 2800-2813, 2820-2829, 2837-2845, 2853-2859, 2867-2873, 2903-2909, 2916-2981, 2983-3091, 3095-3352, 3354-3466, 3468-3574, 3577, 3583, 3587-3588, 3596-3723, 3727-3731, 3735-3741, 3743-3770, 3772-3777, 3780-3787, 3792, 3801-3883, 3885-3896, 3899-3918, 3920-3927, 3930-3933, 3936-3941, 3943-3950, 3952-3956, 3958-3969, 3971-4028, 4030-4042, 4044-4051, 4053-4059, 4061-4069, 4072-4086, 4088-4089, 4091-4097, 4099, 4101, 4104, 4110-4111, 4113, 4116-4120, 4126-4129

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*****Group 5*****
C32	SXC01964-02173, 2175-2267

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3E5239	RELAY AS
1	3S2093	STRAP-CABLE
1	4P7581	CLIP-LADDER
2	5P0537	WASHER-HARD
2	6V8185	NUT-FULL
1	7E3222	MOUNT-SHOCK
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	3E5239	RELAY AS
1	3S2093	STRAP-CABLE
1	4P7581	CLIP-LADDER
2	5P0537	WASHER-HARD
2	6V8185	NUT-FULL
1	7E3222	MOUNT-SHOCK
1	3262696	SOFTWARE GP-ELEK
1	3265979	SOFTWARE GP-ELEK
1	3265980	SOFTWARE GP-ELEK
1	3265981	SOFTWARE GP-ELEK
1	3366693	SOFTWARE GP-ELEK
1	3379427	SOFTWARE GP-ELEK
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 3*****
1	3E5239	RELAY AS
1	3S2093	STRAP-CABLE
1	4P7581	CLIP-LADDER
2	5P0537	WASHER-HARD
2	6V8185	NUT-FULL
1	7E3222	MOUNT-SHOCK
1	3262696	SOFTWARE GP-ELEK
1	3265980	SOFTWARE GP-ELEK
1	3265981	SOFTWARE GP-ELEK
1	3366693	SOFTWARE GP-ELEK
1	3379427	SOFTWARE GP-ELEK
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 4*****
1	3E5239	RELAY AS
1	3S2093	STRAP-CABLE
1	4P7581	CLIP-LADDER
2	5P0537	WASHER-HARD
2	6V8185	NUT-FULL
1	7E3222	MOUNT-SHOCK
1	3262696	SOFTWARE GP-ELEK
1	3265979	SOFTWARE GP-ELEK
1	3265980	SOFTWARE GP-ELEK
1	3265981	SOFTWARE GP-ELEK
1	3366693	SOFTWARE GP-ELEK
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 5*****
1	3E5239	RELAY AS
1	3S2093	STRAP-CABLE
1	4P7581	CLIP-LADDER
2	5P0537	WASHER-HARD
2	6V8185	NUT-FULL
1	7E3222	MOUNT-SHOCK
1	3262696	SOFTWARE GP-ELEK
1	3265979	SOFTWARE GP-ELEK
1	3265980	SOFTWARE GP-ELEK
1	3265981	SOFTWARE GP-ELEK
1	3366693	SOFTWARE GP-ELEK
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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Give careful attention to the groups and the serial numbers to determine the appropriate updates for each genset. Refer to the attached Rework Procedure for details on the following repairs/procedures.

GROUP 1
SECTION I - ECM Power Shutoff Relay Repair Procedure

GROUP 2
SECTION I - ECM Power Shutoff Relay Repair Procedure
SECTION II - ECM Flashfile Update Procedure

GROUP 3
SECTION I - ECM Power Shutoff Relay Repair Procedure
SECTION II - ECM Flashfile Update Procedure
SECTION III - EMCP MPU Speed Signal Cable Procedure

GROUP 4
SECTION I - ECM Power Shutoff Relay Repair Procedure
SECTION II - ECM Flashfile Update Procedure

GROUP 5
SECTION I - ECM Power Shutoff Relay Repair Procedure
SECTION II - ECM Flashfile Update Procedure
SECTION III - EMCP MPU Speed Signal Cable Procedure

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 1.0-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 1.5-hour job for Group 2

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 3

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 4

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 5

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 ISOLATING A 3E-5239 ECM POWER SHUTOFF RELAY ON CERTAIN C27, C32, AND PMC32 GENSETS AND FLASHING THE ENGINE ECM WITH UPDATED SOFTWARE AND REWIRING THE MAGNETIC PICK-UP CABLE ON CERTAIN C32 GENSETS WITH EMCP 3.X

MODELS INVOLVED - C27, C32, and PMC32 GENSETS

Dear Caterpillar Product Owner:

The ECM Power Shutoff Relay used in the power distribution panel needs to be replaced and remounted on the products listed below. The existing relay can fail early due to excessive vibration. In addition, new ECM engine software is available for reflashing the engine ECM to address a potential no start condition.

Some EMCP 3.X Magnetic Pick-Up speed signal cable may also need to be reworked. The existing wiring configuration may cause electrical noise interfering with starting the unit.

Please refer the dealer to their Service Letter dated 24Nov2008 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 24Nov2008 Service Letter

Rework Procedure

Section I: ECM Power Shutoff Relay Repair Procedure

1. Locate the battery disconnect switch. Identify the bracket of the power distribution panel that has the 3E-5239 relay which needs the mounting of the relay modified. If the bracket part number is 260-9524 and looks like Image 1.1.1 no further action for the power shutoff relay is necessary. Perform the next rework item listed in the action required as applicable. If the bracket of the power distribution panel is 282-4356 and looks like Image 1.1.2 proceed with step 2.

NOTE: The power distribution panel shown in Image 1.1.1 does not use the 3E-5239 relay.

Image1.1.1

Image1.1.2

2. Remove all power to the engine following local lock out tag out procedures. Remove power at the power distribution panel through the battery disconnect switch or remove the negative cable from the battery.

3. Remove the cover from the top of the power distribution panel to gain access to the 3E-5239 relay and harness connection.

4. Remove the 3E-5239 relay from the power distribution bracket. Disconnect the engine harness from the relay. Do not reuse the relay.

5. A new mounting hole location (A) is required for the installation of a new 3E-5239 relay with an isolation mount. See Image 1.3.1. Measure 35mm (1 3/8 inch) toward the engine block from the existing original hole (B). Center punch the new location (A) before drilling a 12mm (7/16 inch) hole in the support bracket.

NOTE: Care must be taken not to damage existing parts, ie: circuit breakers, wiring harnesses, etc.

Image1.3.1

6. Assemble ladder clip and relay as shown in Image 1.4.1 and Image 1.4.2.

Assemble the new 3E-5239 Relay Bracket (2) to the 4P-7581 Ladder Clip (3) to the 7E-3222 Shock Mount using a 5P-0537 Washer with a 6V-8185 Nut as shown in Image 1.4.1 and Image 1.4.2. Tighten the nut to a torque of 5.5 +/- 1 Nm (48 +/- 8 lb in). Using a 3S-2093 Tie Strap (1) tightly strap relay and ladder clip together. Trim excessive tie strap using the proper tie strap tool.

Image1.4.1

Image1.4.2

7. Reconnect the wiring harness disconnected in step 4 to the new 3E-5239 relay. Once this connection is completed, install relay assembly (shock mount end) into the new hole location (A) from Step 5 Image 1.3.1. The bottom of the 3E-5239 relay must be positioned in a downward orientation without straining the harness wires prior to completing the installation to the bracket using 5P-0537 washer and the 6V-8185 nut. Tighten the nut to a torque of 5.5 +/- 1 Nm (48 +/- 8 lb-in).

8. Add additional tie straps as needed to eliminate potential interference between the wiring harness(es) and adjacent parts.

9) Reassemble the cover removed in step 3 on the power distribution panel.

10) Remove all lock out tag out procedures where used. Reinstall the negative cable to the battery if removed in step 2. Apply power at the power distribution panel through the battery disconnect switch.

Section II: ECM Flashfile Update Procedure

1. Flash the ECM using the latest version of ET (Version 2007A minimum) with the appropriate software listed in either Image 1.6.3 - Table 1 C32 Flashfiles; and Image 1.7.1 - Table 2 C32 Flashfiles

CAUTION: On certain C32 engines, special attention must be considered when flashing the engine ECM with the 337-9427 Flashfile, 60 Hz, 253-7557 engine arrangement equipped with a higher restriction 267-6161 exhaust system and 147-6618 Exhaust Elbow. Failure to flash the ECM with the correct flashfile will result in unecessary engine derate. When referencing Image 1.6.3 - Table 1: C32 Flashfiles to select the correct new flashfile, do NOT rely only on ET and the existing ECM flashfile to determine which new flashfile is correct. Inspect the exhaust elbow to aid in verifying the correct flashfile.

Reference Image 1.6.1 for photo of 147-6618 Exhaust Elbow. Reference Image 1.6.2 for photo of 236-1161 Exhaust Elbow.

Image1.6.1

Image1.6.2

Image1.6.3

Caution must be taken when selecting either 337-9427 or 326-5979 Flashfile from Image 1.6.3; Table 1 C32 Flashfiles. Verify the engine serial number, existing ECM flashfile and rating, including verification of the exhaust elbow part number. Failure selecting the correct flashfile could result in unnecessary engine derate.

Notes for Image 1.6.3:
(1) 337-9427 flashfile: C32 60 Hz Parts Service Only (PSO) to replace field software on 60 Hz, Tier 2 engine arrangements (253-7557) that have the higher restriction exhaust system 267-6161 and exhaust elbow 147-6618, Reference Image 1.6.1.

(2) 326-5979 Flashfile: C32 60Hz Tier 2 engine arrangements (253-7557) that have exhaust elbow 236-1161, Reference Image 1.6.2.

Image1.7.1

Section III: EMCP MPU Speed Signal Cable Procedure

This procedure 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 1.8.1), 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.

Image1.8.1

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 1.9.1

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 1.9.2

Image1.9.1

Image1.9.2

Situation 3 - Servicing a panel with a Remote Wall Mount EMCP 3.x. as shown in Image 1.10.1

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 1.10.2.

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.