PRODUCT SUPPORT PROGRAM FOR REWIRING THE JACKET WATER HEATER WIRING ON CERTAIN G3406 AND G3406C GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWIRING THE JACKET WATER HEATER WIRING ON CERTAIN G3406 AND G3406C GENERATOR SETS

Usage:

REBE7320-00

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11Aug2011

U-329

A-272

D-292

O-284

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWIRING THE JACKET WATER HEATER WIRING ON CERTAIN G3406 AND G3406C GENERATOR SETS
1383 1408		PS43345

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43345" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

31Aug2013

PROBLEM

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The existing wiring of the jacket water heater can be incorrect for 120VAC voltage configuration on certain G3406 and G3406C Generator Sets. If the existing wiring is incorrect for 120VAC the jacket water heater will only provide a fraction of its designed power, which may be insufficient to achieve desired preheat temperatures.

AFFECTED PRODUCT

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Model	Identification Number
G3406	KAR00487-00599
G3406C	R7E00130-00149

PARTS NEEDED

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Qty	Part Number	Description
2	2L8075	TERMINAL
1	WIRE	14 AWG STRANDED COPPER - 300V
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 14% 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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Refer to the Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-10000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-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.

Rework Procedure

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Refer to the Service Manual if/as required.

Step 1 - Isolate the Genset before commencing any work on the unit, open the Genset breaker, activate the Emergency Stop, and disconnect the battery cables.

Ensure all 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.

Only qualified repair personnel should service this equipment.

Step 2 ? Locate the Jacket Water Heater (JWH) and remove the plastic cover on the JWH terminal box.

Step 3 ? Confirm the actual wiring configuration of the JWH. The JWH will be configured for either 120VAC or 240VAC. Refer to Image1.1.1, Image1.2.1, and Image1.3.1.

Image1.1.1

Image1.1.1: Wiring configuration for 240VAC

Image1.2.1

Image1.2.1: Wiring configuration for 120VAC

Image1.3.1

Image1.3.1: Wiring schematics for 120VAC or 240VAC

Step 4 ? Confirm the actual JWH supply voltage being provided by utilizing a suitable meter. Refer to Image1.3.1.

Step 5 - If the JWH supply voltage measures 120VAC and the JWH wiring configuration is set for 240VAC, the JWH wiring must be reconfigured for 120VAC operation.

Step 6 ? Turn Off the JWH supply voltage source.

Step 7 ? Reconfigure the JWH wiring for 120VAC. Refer to Image1.2.1, and Image1.3.1.

Note: Create the jumper conductor which connects between Terminal post number 2 and Terminal post number 4. The jumper is to be constructed from 14 AWG wire. Utilize a 25mm long piece of wire with a 5mm ID ring terminal crimped on each end of the wire. Move the black wire from Terminal post number 4 to Terminal post number 3.

Step 8 ? Install the JWH terminal box cover.

Step 9 ? Turn On the JWH supply voltage source.

Step 10 - Energize the JWH system to confirm proper operation. Measure the coolant temperature at the jacket water heater outlet side. The coolant temperature entering the jacket water heater should settle between 90F to 130F, dependent on ambient temperature and thermostat setting.

Step 11 - Restore the genset to its proper operational condition.