PRODUCT SUPPORT PROGRAM FOR REWORKING THE MOTORIZED LOUVERS ON CERTAIN C27 AND C32 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE MOTORIZED LOUVERS ON CERTAIN C27 AND C32 GENERATOR SETS

Usage:

TEBE1899-00

Show/hide table

26Aug2014

U-497

Show/hide table

*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE MOTORIZED LOUVERS ON CERTAIN C27 AND C32 GENERATOR SETS
7274		PS44458

Show/hide table

NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS44458" 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.

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

TERMINATION DATE

31Aug2016

PROBLEM

Show/hide table

The existing configuration for the motorized louvers may allow the lovers to fail closed on certain C27 and C32 Generator Sets. If the existing motorized louver fails closed it may cause the package to overheat during operation.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
C27	GDS00280, 301, 336, 403, 416, 422, 427, 439, 442, 448, 464, 495, 529, 533, 544, 551
C32	JAZ01185, 1269, 1468-1469, 1551, 1575, 1580, 1583, 1588, 1694, 1713

PARTS NEEDED

Show/hide table

No parts needed for this program

ACTION REQUIRED

Show/hide table

Refer to the attached Rework Procedure.

Show/hide table

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%
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 2.5-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

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

Rework Procedure for Louver Assembly with Motorized Damper 396-5818

Tools required: 10mm socket, phillip head screw driver, needle nose pliers or channel locks, 3/8" nut driver or socket with extension.

1) Remove access panel on right side (from louver end) of enclosure.

Image1.3.1

2) Visually inspect damper assembly. Verify damper blades are in the closed position with battery power disconnected. If damper blades are in the open position with battery power disconnected, proceed to test portion of this procedure.

3) Damper actuators and mechanical linkages can be configured in two ways:

A) With the mechanical linkage bracket facing down, the actuator will be oriented with the counter clockwise (CCW) side facing in towards the enclosure (see Image1.5.1).

B) With the mechanical linkage bracket facing up, the actuator will be oriented with the clockwise (CW) side facing in towards the enclosure (Image1.5.2).

Image1.5.1

Image1.5.2

4) Remove shaft stop retaining clip from actuator.

Image1.6.1

Image1.6.2

5) Loosen two nuts using 10mm wrench on shaft stop and slide shaft stop assembly down damper shaft.

Image1.7.1

6) Remove self-tapping sheet metal screws from actuator support bracket and remove support bracket.

Image1.8.1

Image1.8.2

7) Remove shaft spring clip.

Image1.9.1

8) Remove actuator from damper shaft.

Image1.10.1

9) Remove hard stop from actuator. Note position of hard stop on actuator. (should be approximately two notches under the 9 position)

Image1.11.1

10) Rotate actuator to the correct orientation (CW if mechanical linkage bracket is up or CCW if mechanical linkage bracket is down) and reinstall hard stop at two notches under the 9 position.

Image1.12.1

11) Reinstall adjusted actuator back on damper shaft in correct orientation.

Image1.13.1

12) Reinstall shaft spring clip (shaft spring clip should be installed before actuator support bracket).

Image1.14.1

13) Reinstall actuator support bracket with self-tapping sheet metal screws.

Image1.15.1

14) Manually open damper blades by rotating damper shaft.

Image1.16.1

15) Reinstall shaft stop on actuator. Shaft stop should be set to the 1 position.

Image1.17.1

Image1.17.2

16) Tighten two bolts with 10mm socket on shaft stop. Ensure full engagement to allow access to re-install retaining clip back into place. (Step 17)

Image1.18.1

17) Reinstall shaft stop retaining clip.

Image1.19.1

Image1.19.2

18) Rework is now complete. Repeat process for second actuator and (if installed) third actuator.

Additional Rework Required for Units with EMCP 4.2

1) Open AC/DC panel using flat head screwdriver.

Image1.21.1

2) Locate 2 red wires landed on terminal blocks RO8-NC and RO8-C. Use small flat head screwdriver to remove wire from the RO8-NC terminal block and insert wire into RO6-NO terminal block.

Image1.22.1

3) Repeat removal for wire located in RO8-C terminal block and insert into RO6-C terminal block.

4) Ensure EMCP 4.2 setting for Relay Output 6 in control panel is set for "Disable Aux AC Supply", by "View" the "I/O Status" for "Relay Outputs" then scroll to #6.

Image1.24.1

Test Procedure (EMCP 4.2 and EMCP 4.3 and 4.4)

1) After completion of rework, test operation of motorized damper assembly and control circuit.

2) Battery disconnect should be in the "On" position and engine should not be running. In this configuration the damper blades should be in the closed position.

Image1.26.1

3) Start engine to verify damper blades open. When damper blades are completely open, (< 20 sec) stop engine. Damper blades should then return to the closed position (< 75 sec).

4) To simulate loss of power, toggle breaker to the "Off" position. Breaker is located inside the relay panel mounted on the enclosure (see picture below). This breaker removes the 24V power from the actuators. Confirm damper blades open upon loss of power.