PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DC INTERCONNECTING LEAD AND THE MCS CONTROL PANEL CAPACITOR MOUNTING ADAPTOR ON CERTAIN C4.4 MARINE GENSETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DC INTERCONNECTING LEAD AND THE MCS CONTROL PANEL CAPACITOR MOUNTING ADAPTOR ON CERTAIN C4.4 MARINE GENSETS

Usage:

REBE4869-00

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23Feb2009

U-82

A-72

D-68

O-71

TM-3

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DC INTERCONNECTING LEAD AND THE MCS CONTROL PANEL CAPACITOR MOUNTING ADAPTOR ON CERTAIN C4.4 MARINE GENSETS
1403 7490 4490 1408		PI31637

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31637" 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 "PI31637" 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:

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COMPLETION DATE	TERMINATION DATE
31Aug2009	28Feb2010

PROBLEM

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The existing DC interconnecting lead from the MCS wiring harness can short internally on certain C4.4 Marine Gensets. If the existing wiring harness shorts, it can lead to failure of the MCS control module. In addition, the capacitor mounting adaptor from the MCS control panel can fail, which may prevent the genset DC electrics from being fully insulated.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	L1K00180-00181, 218, 239-240, 246-247 S1M00267-00268, 282-283, 310, 314-315, 321, 324, 327, 368-371, 395-397, 400, 402, 435, 456, 459, 485, 489-490, 504-505, 558-559, 568, 643-645, 647, 664-665, 692-694, 697-702, 704, 710, 712-716, 722

PARTS NEEDED

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Qty	Part Number	Description
1	2886119	HARNESS AS-WIRE
1	3073489	PILLAR
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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Replace the 288-6119 DC Interconnecting Lead with a new part of the same part number.

Replace the existing capacitor mounting adaptor.

NOTE: Stop the genset from the MCS control module and take it out of "Auto" mode if a remote panel is connected. Switch battery disconnect key switch on the breaker/relay box to the DISCONNECT position. Turn OFF the DC electrics by using the 8H-5306 Key supplied with the genset.

Replacement of 288-6119 DC Interconnecting Lead:

1. Disconnect the 288-6119 DC Interconnecting lead from the engine.

2. Disconnect the 288-6119 DC Interconnecting lead from the underside of the MCS control box. Do not reuse.

3. Connect the replacement 288-6119 DC Interconnecting Lead to the connector on the underside of the MCS control box, then to the engine connector.

Replacement of the 307-3489 Capacitor Mounting Adaptor:

1. Use the 290-5533 Key supplied with the genset to open the control box door and gain access to the capacitor. The capacitor is mounted in the top right hand corner of the MCS control as circled in Image1.

2. Remove the screws securing the black and red cable terminals to the capacitor and unscrew the capacitor by turning it counter-clockwise by hand.

3. Remove the capacitor from the control box and unscrew the steel adaptor from the mounting stud.

4. Screw the white plastic mounting adaptor to the capacitor as shown in Image2.

5. Refit the adaptor and capacitor to the mounting stud in the control box by hand until tight.

6. Re-secure the cable terminals to the capacitor, ensuring that the red cable is on the capacitor terminal marked "+" and the black cable is on the terminal with no markings, as shown in Image3.

7. Ensure that all tools are removed from the control box, close and lock the door.

8. Return the genset to service: Turn ON the DC electrics using the 8H-5306 Key. Switch the battery disconnect key switch on the breaker/relay box to the CONNECT position. Return the MCS control module to "Auto" mode if a remote panel is connected.

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Image1

Image2

Image3

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
Reasonable travel and mileage will be allowed. If there are multiple gensets in a boat, please note all serial numbers installed in the boat in the claim story, only one trip will be allowed per boat to rework all units.

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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 REPLACING THE DC INTERCONNECTING LEAD AND THE MCS CONTROL PANEL CAPACITOR MOUNTING ADAPTOR ON CERTAIN C4.4 MARINE GENSETS

MODELS INVOLVED - C4.4 Marine Genset

Dear Caterpillar Product Owner:

The DC interconnecting lead and the control module capacitor mounting adaptor need to be replaced on the products listed below. 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 23Feb2009 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 23Feb2009 Service Letter