PRODUCT SUPPORT PROGRAM FOR INSTALLING A MISSING RS485 REMOTE ANNUNCIATOR WIRING GROUP ON CERTAIN 3516, 3516B, 3516C, AND C175-16 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A MISSING RS485 REMOTE ANNUNCIATOR WIRING GROUP ON CERTAIN 3516, 3516B, 3516C, AND C175-16 GENERATOR SETS

Usage:

REBE8869-01

Show/hide table

11Oct2012

(Revised 04Sep2013)

U-536

A-425

O-492

Show/hide table

*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR INSTALLING A MISSING RS485 REMOTE ANNUNCIATOR WIRING GROUP ON CERTAIN 3516, 3516B, 3516C, AND C175-16 GENERATOR SETS
1404 1408 4459		PS52308

Show/hide table

NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52308" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 11Oct2012 Service Letter. Changes have been made to the Affected Product.

Show/hide table

TERMINATION DATE

31Oct2014

PROBLEM

Show/hide table

The RS485 remote annunciator 3726303/">372-6303 Wiring Group was not installed on certain 3516, 3516B, 3516C, and C175-16 Generator Sets. The 3726303/">372-6303 Wiring Group is required to be able to use and install the RS485 remote annunciator.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
3516	YAS00509-00510, 520, 530, 532
3516B	YAT00756-00757 YAW00389-00390, 392, 409
3516C	SBJ01360, 1380-1382, 1385-1390, 1393-1394, 1396, 1400, 1407-1409, 1411-1413, 1415-1422, 1424 SBK01351, 1354, 1356-1360, 1362-1363, 1365-1368, 1372-1375, 1377, 1380-1382, 1384-1391
C175-16	WYB01025, 1027-1028, 1049, 1054, 1056, 1123-1124, 1126-1127

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	3726303	WIRING GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 10% 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

Show/hide table

The 3726303/">372-6303 Wiring Group is needed for the remote annunciator to work. If there are no plans to use a remote annunciator on an existing unit, this rework will not be required.

3726303/">372-6303 Wiring Group consists of the following parts:

Qty Part Number Description

4 314-9098 BLOCK-TERMINAL
1 372-6305 TAG-SIGNAL
1 372-6304 HARNESS AS
1 372-6306 HARNESS AS

Refer to the attached Rework Procedure.

Image1 shows an AC/DC box with the wiring group installed.

Show/hide table

Image1

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 1.5-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

Show/hide table

1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. 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 operation and disconnect/lockout all power sources before commencing any work.

2. Locate the DC terminal strip inside the AC/DC box. Refer to Image 1.1.1.

Image1.1.1

3. Install four 314-9098 Terminal Blocks and 372-6305 Signal Tag. Refer to Image1.1.1 and Image1.2.2.

4. Install 372-6306 Harness, connect wires on terminal blocks and insert harness inside the right hand panduit. Refer to Image1.2.1 and Image1.2.3.

5. Connect 372-6304 Harness on the left side of the terminal blocks. Refer to Image1.2.2 and Image1.2.3.

Image1.2.1

Image1.2.2

Image1.2.3

6. Remove the generator top box cover and side extension top covers. Route 372-6304 Harness from the AC/DC box to the EMCP 4 along the inside of generator box using tie straps to secure harness. Refer to Image1.3.1 and Image1.3.2.

Image1.3.1

Image1.3.2

7. Locate the EMCP 4.2 panel. Inspect EP-C1 8 pin connector on EMCP harness to ensure wire G408-EP (Black) is in pin 1 and wire G407-EP (Red) is in pin 2. Refer to Image1.4.1. If wires are not in the right location on the pins, swap the wires.

8. Inspect EP-C20 70 pin connector on the EMCP to ensure G408-EP (Black) is in pin 49 and wire G407-EP (Red) is in pin 59. Refer to Image1.4.1. If wires are not in the right location on the pins, swap the wires.

Image1.4.1

9. Connect LD-C1 (8 pin) connector on 372-6304 Harness to EP-C1 (8 pin) connector on EMCP 4.2 harness. Refer to Image1.5.1.

Image1.5.1

10. Perform a continuity test on the two RS485 wires coming from the EP-C20 (70 pin) connector located in the back of the EMCP4.2 panel (Image1.4.1) to the AC/DC box terminal block (Image1.2.3) to make sure that wiring is correct.

11. Install top box covers and tighten the bolts.