PRODUCT SUPPORT PROGRAM FOR REPLACING THE STARTING AND OPTIONAL RELAY ON CERTAIN 3412C GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE STARTING AND OPTIONAL RELAY ON CERTAIN 3412C GENERATOR SETS

Usage:

TEBE4317-00

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06May2016

A-170

D-203

O-194

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE STARTING AND OPTIONAL RELAY ON CERTAIN 3412C GENERATOR SETS
4493 4460 7426		PS45061

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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 "PS45061" 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

31May2017

PROBLEM

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If the existing relay fails it can/will disable the ability to start the generator set and/or operate an optional circuit on certain 3412C Generator Sets.

AFFECTED PRODUCT

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Model	Identification Number
3412C	DK600102-00151, 159, 169

PARTS NEEDED

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Qty	Part Number	Description
2	3368570	DIODE (if needed)
2	3368571	RETAINING CLAMP (if needed)
2	3715027	BASE-RELAY
2	3715029	RELAY
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 attached 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%
0-2000 hrs, 0-24 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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1. Ensure the genset has been isolated from all energy sources and secured in accordance with proper lock out tag out procedures.

2. Identify the incorrect AC relay and base as per below (Image 1.2.1).

Image1.2.1

3. Replace above parts with DC relay p/n 371-5029 and base p/n 371-5027 as shown below (Image 1.3.1). (Spare diode 336-8570 and clamp 336-8571 are included in the bulletin in case they are damaged upon removal.) Re-wire the new relay as per the following:

Wire CR NO 14 terminates at Pin number 14
Wire CR 11 CON terminates at Pin number 11
Wire CR A2 terminates at Pin number A2
Wire R12 terminates at Pin number A1

Image1.3.1

4. To confirm correct wiring. Reconnect battery and pull open the fuse holder F3 (20A) (Image 1.4.1), this disconnects the starter motor solenoid(s).

Image1.4.1

5. Press the start button on the front of the control panel. The panel will start to try and crank the engine. You should hear a ?relay click? from the CR relay located in the control box of the panel and the LED on the diode of the CR relay should light up green during the crank sequence (Image 1.5.1).

Image1.5.1

If this happens then relay has energised and the relay has been correctly replaced.
If it does not work, please begin fault finding as some of the re-connections made may not be correct.

One of the following options may also be fitted and the AC relay will again need swapped out. If an option is fitted, replace and re-wire according to the specific option instructions below:

R2 relay - Breaker motor operator relay
Wire M-T6 STNC-GY NO_14 to Pin number 14
Wire M-T5 10-GY COMM_11 to Pin number 11
Wire M-T11 229-GY A2 to Pin number A2
Wire M-T10 E565-GY A1 to Pin number A1

R4 relay - Common Alarm relay
Wire L-T12 CMALM1 GY CMA_NO_14 to Pin number 14
Wire L-T13 CMALM3-GY CMA_COM_11 to Pin number 11
Wire L-T11 CMALM2-GY CMA_NC_12 to Pin number 12
Wire L-T4 229-GY CMN_ALARM_A2 to Pin number A2
Wire L-T3 101-GY CMN_ ALARM_A1 to Pin number A1

R5 relay - Generator Running Relay
Wire G-T1 GRRNO-GY GRR_NO_14 to Pin number 14
Wire G-T2 GRRC-GY GRR_COM_11 to Pin number 11
Wire G-T8 GRRNC-GY GRR_NC_12 to Pin number 12
Wire G-T7 229-GY GRR_A2 to Pin number A2
Wire G-T6 Y911-GY GRR_A1 to Pin number A1