PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL LEVEL GAUGE ON CERTAIN C15, C18, C27, AND C32 GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL LEVEL GAUGE ON CERTAIN C15, C18, C27, AND C32 GENERATOR SETS

Usage:

TEBE1968-01

11Sep2014
(Revised 03Nov2014)


U-526
A-394
D-473
O-447

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL LEVEL GAUGE ON CERTAIN C15, C18, C27, AND C32 GENERATOR SETS

1273 1408
PS44475
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 "PS44475" 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.

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.

 
NOTE:

This Revised Service Letter replaces the 11Sep2014 Service Letter. Changes have been made to the Affected Product.


TERMINATION DATE

30Sep2016

PROBLEM

On certain C15, C18, C27, and C32 Generator Sets equipped with a 422-6068 or 422-6867 Fuel Level Gauge, the connector has pins 1 (A) and 3 (C) reversed.

AFFECTED PRODUCT

Model Identification Number
C15  NAP00178, 180, 228-229, 234, 246
C18  NAW00150, 155, 157-158, 177
C27  GDS00101-00102, 114, 126, 129, 135, 149-152, 166, 168, 176, 183, 216, 219, 221, 227, 256-257, 259, 263, 265, 280, 315, 318, 320-323, 340, 352-353, 357-360, 381, 397-400, 407, 456, 458, 466
C32  JAZ00932, 1185, 1189, 1196, 1198, 1269, 1273-1274, 1282, 1343, 1359, 1439, 1575, 1609, 1613

PARTS NEEDED

No parts needed for this program

ACTION REQUIRED

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-20000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
This procedure has been created for the inspection and operational correction of the 422-6068 or 422-6867 Fuel Level Gauge used on certain C15, C18, C27, and C32 Generator Sets with installed fuel tanks. The gauge itself may be mis-wired and not function as intended. This procedure outlines how to locate, inspect, diagnose, and correct this issue. Before proceeding, please ensure that the fuel level monitoring harnessing package has been properly installed on the unit.

WARNING: ALWAYS USE CAUTION WHEN WORKING WITH OR AROUND DIESEL FUEL. DIESEL FUEL IS HIGHLY FLAMMABLE. ALWAYS WEAR PROPER PERSONAL PROTECTIVE EQUIPMENT AND ENSURE PROPER SAFETY PRECAUTIONS HAVE BEEN TAKEN BEFORE PROCEEDING WITH ANY OF THE FOLLOWING TESTING OR CORRECTIVE PROCEDURES
 
Procedure

1. Locate the fuel level gauge assembly.

a. C15/C18 Generator Sets ? The gauge should be located on the top, right-side of the fuel tank (as referenced from the engine-right) behind the second maintenance door on the right-side of the canopy enclosure. Installed tanks on these units do not require a canopy enclosure.

b. C27/C32 Generator Sets ? The gauge should be located on the top, right-side of the fuel tank (as referenced from engine-right) behind the second maintenance door on the right-side of the canopy enclosure. Installed tanks for these units required a canopy enclosure.
Image1.2.1
Image1.2.2
 
2. Inspect the gauge assembly making special note of the indicated fuel level on the gauges visual indicator. Save this information as it will be needed for proper positioning and re-assembly of the gauge after testing and/or correction.

3. Locate the manufacturer's part number and date code on the gauge body as shown in the examples below.
Image1.3.1
Image1.3.2
 
The manufacturer's date code numbering system description is as follows:
Part numbers requiring a week-year date code are marked as follows:

XXXX-XXX ABCD

Manufacturer's Part No. Date Code

AB = Week of the year in which the gauge was made
CD = Last two digits of the year in which the gauge was made
(e.g. 2304 = 23rd week of 2004)

I. If the manufacturer's date code is "1814" or greater the gauge has been wired correctly from the manufacturer and the gauge should function properly. Proceed with the following steps to ensure proper operation.

II. If the manufacturer's date code is "1714" or less the gauge may not be wired correctly and further inspection is required. Proceed with the following steps for further inspection.

4. Locate and remove the screws attaching the hall effect sensor to the fuel level gauge body and remove the sensor from the top of the fuel level gauge assembly.
Image1.4.1
Image1.4.2
 
5. Using a magnet, move the gauge until it indicates a level other than completely full or completely empty. Place it aside ensuring that the indicated level is still greater than empty. Note the indicated level for future reference.
Image1.5.1
 
6. Turn the battery disconnect switch to the "ON" position.

7. Locate the unit's EMCP control panel and check for fuel level indication.

a. If the fuel level indicated is approximately the same as what is shown on the sensor's visual gauge then the sensor is functioning properly. Move the indicator to several different indicated fuel levels to ensure complete sensor function. If all of the shown levels on the sensor's visual gauge are approximated by the EMCP, no further inspection is necessary. Proceed to Step 14.

b. If the fuel level does not approximate the level shown on the sensor's visual gauge, proceed with the following steps for inspecting and correcting the gauge itself.
Image1.6.1
Image1.6.2
 
8. Locate the hall effect sending unit top of the fuel level gauge. Make note of the wire landing location markings and their corresponding wire colors on the sending unit.

a. The wire colors and their landing locations should correspond as shown in the Diagram 1 and Table 1. If necessary, refer to Schematic, UENR3939 or UENR4654 for further information.

b. If the wire colors correspond as listed, the inspection is finished and the sensor should function properly. If the EMCP still does not indicate any gauge function, proceed with an inspection of the sensing harness wiring. (Sensing harness wiring inspection is not outlined in this procedure.)

c. If the colors do not correspond as listed, proceed with the following steps to take corrective action.
Image1.7.1
Image1.7.2
 
9. Turn the battery disconnect switch to the "OFF" position.

10. Disconnect the sensor from the sensing harness leading to the EMCP control panel.

11. Remove the connector wedge and, using an electrical pin disconnect tool (shown below), disconnect the mis-landed wires from the sensor connector and re-install them in locations as listed in Table 1.
Image1.8.1
 
12. Re-connect the sensor lead to the sensing harness.

13. Repeat Steps 5, 6 and 7 to check for proper sensor function and indication.

14. Once proper sensor function has been verified, turn the battery disconnect switch to the "OFF" position.

15. Using a magnet, move the sensor to the approximate position noted at the beginning of the procedure. (The gauge assemblies are designed so that the sensors are self-aligning. When the gauge's float is moved throughout its full range of motion, the sensor will align itself with a magnet located on top of the float mechanism. However, since the gauge body was not removed from the tank and, thus, access to the float mechanism is not available, setting the gauge back to the originally noted position will allow for immediate correct indication of the fuel level in the tank without the need for full range cycling of the float mechanism.)

16. Re-install the sensor on to the gauge body noting the orientation of the molded tabs on the sensor for proper installation on the gauge body. Tighten the screws hand-tight (0.5 Nm, 5 in.lb.).

17. Place the unit back into service.
Image1.9.1
Image1.9.2
 
 

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