PRODUCT SUPPORT PROGRAM FOR INSTALLING PRODUCT LINK ON CERTAIN XQ35 RENTAL GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR INSTALLING PRODUCT LINK ON CERTAIN XQ35 RENTAL GENERATOR SETS

Usage:

TEBE5836-00

27Feb2017


U-109

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR INSTALLING PRODUCT LINK ON CERTAIN XQ35 RENTAL GENERATOR SETS

1926 1408 7610 7620 1901
PS45401
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 "PS45401" 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.


TERMINATION DATE

28Feb2019

PROBLEM

Certain XQ35 Rental Generator Sets, the Product Link PLG641 controller was factory short shipped.

AFFECTED PRODUCT

Model Identification Number
XQ35  JK700119, 122, 143, 150, 162, 228-236

PARTS NEEDED

Qty

Part Number Description
1 CONTROLGROUP Controller and Hardware (see Action Required)
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

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.

The PLG controller should have already been provided to the dealer. If the dealer does not have the parts, have the Dealer Technical Communicator (TC) submit a request for the parts to CPI number 381100 through CPI Feedback within the Service Information Management System (SIMSi).

Refer 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 2.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
Installation of the Product Link PLG641

1. Access to installation area

Open side door for battery and battery disconnect switch access.
Reference Image 1.1.1
Image1.1.1
 
Verify battery disconnect switch is in the OPEN / OFF position.
Reference Image 1.2.1
Image1.2.1
 
Disconnect battery power from the rental module by disconnecting the battery negative cable.
Reference Image 1.3.1
Image1.3.1
 
Gain access to the PLG641 installation location.
Reference Image 1.4.1
Image1.4.1
 
Open control panel access door by removing 3 bolts.
Reference Image 1.5.1
Image1.5.1
 
Unlock and open the lower bus bar access door.
Reference Image 1.6.1
Image1.6.1
Image1.6.2
 
Upper right hand corner, locate installation area for PLG641.
Locate 2 pin plug connector and 15 pin connectors.
Reference Image 1.7.1
Image1.7.1
 
2. Wiring Instructions

Modify factory installed 2 pin plug by removing the 2 wires from the connector.
Remove and do not use the connector.
Reference Image 1.8.1
Image1.8.1
 
Cut pins off and strip wires.
Reference Image 1.9.1
Image1.9.1
 
Install supplied Deutsch pins.
Reference Image 1.10.1
Image1.10.1
 
Install wires into supplied Deutsch connector

Position 1: Wire Label A110 (Batt +)
Position 2: Wire Label 206 (Batt -)

Reference Image 1.11.1
Image1.11.1
 
Install Deutsch wedge plug lock.
This modified Deutsch connector will be used to connect to the jumper harness in step 4, mounting and connecting the PLG.
Reference Image 1.12.1
Image1.12.1
 
3. Install Communication Antenna

Loosen and remove mounting hardware from bottom of antenna.
Keep plastic mounting plate with the bottom of the antenna with the locking features pointing away from the bottom of the antenna.
Reference Image 1.13.1
Image1.13.1
 
Remove cables from locking hardware by placing two cables in the notch of the locking nut and pull opposite connector through. Leave one cable in the notch while pulling the next connector through. Then, pull the remaining connector through.

If present, remove and do not use the star washer.

Remove antenna cable mounting rubber plug from top of module.
Reference Image 1.14.1
Image1.14.1
 
Feed the antenna cable through the mounting surface hole. Ensure all parts of the locking feature of the plate fit through the hole.
Reference Image 1.15.1
Image1.15.1
 
Feed the antenna cable through the plastic shoulder washer. Ensure the locking feature of the shoulder washer and plate are able to interlock. This method will assist with controlling the orientation of the antenna relative to the mounting surface.
Reference Image 1.16.1
Image1.16.1
 
Tighten the nut to 5 N.m (3.6 lb ft).
Reference Image 1.17.1
Image1.17.1
 
Antenna installed.
Route the antenna coax cables back to the location of where the PLG641 will be installed.
Reference Image 1.18.1
Image1.18.1
 
4. Mounting and Connecting the PLG641

Install supplied rubber standoff bushing at each of the four nutsert fitting mounting locations.
Reference Image 1.19.1
Image1.19.1
 
Verify SIM card is installed into back of PLG641 device.
Reference Image 1.20.1
Image1.20.1
 
Secure the PLG641 to the standoffs using the provided (QTY 4) lockwasher and (QTY 4) screw.
Reference Image 1.21.1
Image1.21.1
 
Install connectors to PLG641 device using the jumper harness, factory supplied connectors and antenna connections.

Control power harness connections
C1 ? Power 2 Pin connector
Connect Deutsch connector installed from Step 2
Reference Image 1.22.1
Image1.22.1
 
Factory supplied connector
C2 ? CAN / LPM 15 Pin connector

Antenna connectors
3G GPRS BROWN COAX
GPS BLUE COAX

Reference Image 1.23.1
Image1.23.1
 
Secure Power Control Harness and Antenna Cable

Verify back installation area is clean.
Secure adhesive pads to back wall.
Secure antenna cable to side wall using adhesive pads and tie wraps.
Reference Image 1.24.1
Image1.24.1
 
5. Power on procedure

Reconnect battery negative cable.
Turn Battery Disconnect to ON.

Wait approximately 1 minute for the power up sequence to complete and verify the
PLG641 device lights illuminate.

a. Power light will illuminate
b. Red Modem light flashes

Reference Image 1.25.1
Image1.25.1
 
The installed PLG641 device is now ready for dealer registration.

For additional information please reference the following:

Power Net link for PLG
https://engines.cat.com/en/cat-connect0/industries/electric-power/dealer-readiness.html

Special Instruction, M0069806, "Installation Procedure for Cat? Product Link Generation (PLG6x1)"
 
 

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