PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 454-6625 WIRING GROUP ON CERTAIN C15, AND C18 GENERATOR SETS EQUIPPED WITH A DEIF CONTROLLER Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 454-6625 WIRING GROUP ON CERTAIN C15, AND C18 GENERATOR SETS EQUIPPED WITH A DEIF CONTROLLER

Usage:

TEBE2399-00

11Jun2015


A-208

 

Priority

  
  

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 454-6625 WIRING GROUP ON CERTAIN C15, AND C18 GENERATOR SETS EQUIPPED WITH A DEIF CONTROLLER

4459 1408 1439
PI32495
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 as soon as possible. When reporting the repair, use "PI32495" 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 "PI32495" as the Part Number, "7751" as the Group Number, "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.


COMPLETION DATE

TERMINATION DATE

30Jun2015 31Dec2015

PROBLEM

The group 454-6625 Wiring Group needs to be reworked on certain C15, and C18 Generator Sets equipped with a DEIF controller. There is no interconnection of the low coolant level sensor and the DEIF controller and if the generator set has a problem that causes coolant leakage, when the coolant reaches the low level the DEIF controller will not shutdown the generator set, which may cause other problems.

The DEIF wiring diagram was incorrect. The wiring requires the connection of the low coolant level sensor only until the terminal-block a-t210 and not requires interconnection between the terminal-block A-T210 and DEIF controller.

AFFECTED PRODUCT

Model Identification Number
C15  L8B00235-00240, 242-243, 261-264, 269-271, 276-277, 280-282, 302, 309, 321-322, 328-330, 347
C18  L8D00183-00184, 195-205, 213-220, 222, 323-325, 327, 329, 333-335, 340-342, 346, 348, 350-351, 360, 362-363

PARTS NEEDED

Qty

Part Number Description
1 2349425 LINK-TERMINAL
1 BULK_WIRE WIRE qty 220cm (See Rework Procedure)
1 TERMINAL_FERRULE TERMINAL qty 3 (See Rework Procedure)
1 TERMINAL_TWIN_WIRE TERMINAL qty 1 (See Rework Procedure)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

Note: If necessary, contact Glauber Bandeira for wiring drawings.

Email: Bandeira_Glauber_m@cat.com
Phone: +55 19 2106 1193


Important Safety Information

Ensure that all lockout/tagout procedures for the site are followed. Read and understand the Safety Section in the Operation and Maintenance Manual. Ensure the area is safe and free from unwarranted potential hazards. Isolate the battery and mains voltage before starting work.

Perform the interconnection between the terminal block and DEIF controller. Refer to the attached Rework Procedure.

OWNER NOTIFICATION

Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%

 NOTE: This is a 1.5-hour job


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.
 
 
 
EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE 454-6625 WIRING GROUP ON CERTAIN C15, AND C18 GENERATOR SETS EQUIPPED WITH A DEIF CONTROLLER

MODELS INVOLVED - C15 C18

Dear Cat Product Owner:


The group 454-6625 Wiring Group needs to be reworked on certain C15, and C18 Generator Sets equipped with a DEIF controller. There is no interconnection of the low coolant level sensor and the DEIF controller and if the generator set has a problem that causes coolant leakage, when the coolant reaches the low level the DEIF controller will not shutdown the generator set, which may cause other problems. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 11Jun2015 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 11Jun2015 Service Letter


Rework Procedure


 
Remove the wire 7 AT-138 from the terminal block, isolate the cable and hide it inside the wire duct.
Add a terminal link 2.5mm 2-way part number 234-9425 between the wire "AT-137 (5 WH)" and "AT-138 (7 WH)", please see picture below.
Image1.1.1
Image1.1.2
 
Make a wire (image 1.2.1) using 120 cm of cable 0.75mm? according image 1.2.2 and crimping at their tips 2 terminals ferrule characterized according image 1.2.3
This wire will be nominated wire X1.
Image1.2.1
Image1.2.2
Image1.2.3
 
Interconnect the terminal block of wire A-T210/16-A9/A-C1-11 of upper terminal block with the wire A-T49 / 216-A78 / A-T123 of bottom terminal block (image 1.3.1).
Use the wire X1 done in the previous step.
Image1.3.1
 
Make a wire (image 1.4.1)using 100 cm of cable using 120 cm of cable 0.75mm? according image 1.2.2 and crimping at one of their tips 1 terminal ferrule characterized according image 1.2.3.
It will be nominated wire Z1.
Image1.4.1
 
Remove the wire 5-AT35/A111 from position 91 of DEIF controller, isolate it and attach it in the main harness.
Image1.5.1
 
Remove the wire 7-AT73/A128 from the position 44 of DEIF controller, remove the original terminal and crimp a terminal ferrule (twin wire) according image 1.6.1 joining the wire 7-AT73/A128 with the wire Z1 (done in the previous step)and connect it back in the position 44.
Image1.6.1
Image1.6.2
Image1.6.3
 
Connect the other tip of wire Z1 in the position 91 of DEIF controller in place of the wire 5-AT35/A111 removed previous.
 
Start the configuration of DEIF controller

Select the option "Start communication device" indicated by the red arrow.
Select "Service Port (USB)" >>> "DEIF EGC USB to COM"
Image1.8.1
 
Enter the Password "2002"
Image1.9.1
 
Select the option "Parameters" >>>> "Read"
Image1.10.1
 
Select the option "Input" >>>> "Digital Inputs"
Image1.11.1
 
Perform the digital input 77 according showed below:
Select the option "Edit all settings for the parameter" indicated by the red arrow.
Set the timer of 1 sec.
Fail class: Shutdown
Check the box: Enable
High Alarm
Press the button "write" to update the AGC200 controller.
Image1.12.1
 
Select the option "Language".
Change the setpoint from "English" to "Language 1".
Press the button "read from device".
Image1.13.1
 
Press the button "Run"
Select the project file and wait the progress.
Image1.14.1
 
To the column "Master Language" line "Digital Input 77" type the text "Low coolant Level" on column Language 1.
To the column "Master Language" line "Digital Input 77 OFF" type the text "Low coolant Lev OFF" on column Language 1.
To the column "Master Language" line "Digital Input 77 ON" type the text "Low coolant Lev ON" on column Language 1.

After type the text click in the option "WRITE LANGUAGE TO THE DEVICE".
Image1.15.1
 
Select "Language 1" on the language selection box.
Click "OK".
Image1.16.1
 
Start the generator set and test the low coolant level shutdown by grounding the low coolant sensor.
 
 

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