PRODUCT IMPROVEMENT PROGRAM FOR REPLACING DEFECTIVE RFI FILTERS ON CERTAIN 3406C, 3408C, 3412C MARINE AUXILIARY GENSETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING DEFECTIVE RFI FILTERS ON CERTAIN 3406C, 3408C, 3412C MARINE AUXILIARY GENSETS

Usage:

REBE2330-00

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05Sep2007

A-357

D-354

O-379

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING DEFECTIVE RFI FILTERS ON CERTAIN 3406C, 3408C, 3412C MARINE AUXILIARY GENSETS
4479		PI31341

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31341" 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 "PI31341" 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
31Mar2008	30Sep2008

PROBLEM

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The existing 9Y-0968 RFI Filter can cause an over voltage upon start up. The 9Y-0968 RFI Filter needs to be diagnostic checked and, if found to be defective, replaced with a new 1215421/">121-5421 RFI Filter on certain 3406C, 3408C, 3412C marine auxiliary gensets.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3408C	TAM00416-00421, 424-427, 445-455
3412C	RLR00421-00427, 437-439, 442-461, 463, 471-474, 476

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*****Group 2*****
3406C	PFH00902

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1215421	FILTER AS-RFI
*****Group 2*****
1	1215421	FILTER AS-RFI

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

NOTE: This is a 2.0-hour job for Group 1
Reasonable travel and mileage is covered. Please note the serial number of the sister engine(s) installed on the vessel in the warranty claim. Only one trip will be covered per vessel.

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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 2.0-hour job for Group 2
Reasonable travel and mileage is covered. Please note the serial number of the sister engine(s) installed on the vessel in the warranty claim. Only one trip will be covered per vessel.

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 REPLACING DEFECTIVE RFI FILTERS

MODELS INVOLVED - 3406C, 3408C, 3412C MARINE AUXILIARY GENSETS

Dear Caterpillar Product Owner:

The RFI Filter needs to be inspected and, if necessary, replaced on the products listed below. The existing RFI filter can cause an over voltage upon start up. 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 05Sep2007 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 05Sep2007 Service Letter

Rework Procedure

Warning: Refer to the safety information in Generator Operation and Maintenance Manual (Media Number: SEBU7842 for PFH, SEBU7843 for TAM, and RLR) before starting this repair.

Note: Make sure the unit is off-line (disconnected from utility and/or other generators power service), and locked out. Only qualified electrical personnel should service the equipment.

1.) Remove top generator control cover to gain access to the 9Y-0968 RFI Filter.

2.) Discharge bus bar and cable capacitance before touching any power lead.

3.) Disconnect the 6 power leads from the terminals of the filter, as shown in the picture below:

Image1.1.1

4.) Perform diagnostic test of the filter in order to determine if the unit is defective, as follows:

a. Test Continuity by setting VOM to lowest resistance scale (e.g., 1x, 10x, etc.)

b. Using a VOM set to the 'lowest resistance scale' measure the resistance from BS1-22 and/or BS2-22 to the metal case (Chassis Ground) as shown in the picture below:

Image1.2.1

c. If the resistance reading is ?infinite-ohms? or maximum resistance, the RFI Filter is not defective and does not need to be replaced. If this is not the case, continue to Step d.

d. If the resistance reading is 'zero-ohms' or continuity, the RFI Filter is defective. The defective filter should be marked as defective and replaced with a new filter. Follow the removal procedure in steps 5 and 6 below.

5.) Remove the four bolts indicated in the picture below from the mounting bracket to gain the access to the mounting nuts of the filter.

Image1.3.1

6.) Remove the four bolts that hold the defective filter to the mounting bracket and replace with new.

7.) Installation of the new 1215421/">121-5421 RFI Filter is the reverse of the removal procedure.