Usage:
11Nov2014 |
Before/After Parts stock action needed | PRODUCT SUPPORT PROGRAM FOR REPLACING THE CONTROL PANEL CIRCUIT BOARD ON CERTAIN C2.2 RENTAL GENERATOR SETS |
|
4490 7451 7750 | PS44546 |
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 "PS44546" 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: | When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code. |
NOTE: | Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible. |
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 |
30Nov2015 |
PROBLEM
Certain C2.2 Rental Generator Sets are experiencing unexpected random shutdown events. This is due to the printed circuit board (PCB) mounted logic relays used in the assembly of the existing 266-5825 Circuit Board being susceptible to sudden shock/impact or excessive vibration. |
AFFECTED PRODUCT
Model | Identification Number |
C2.2 | GBE01201, 1206, 1215, 1244, 1246-1249, 1251-1253, 1256-1262, 1267-1269, 1272, 1274-1277, 1280-1282, 1285-1286, 1289-1296, 1301-1304, 1352, 1365-1366, 1368-1369, 1373, 1375-1377, 1387, 1389, 1399, 1402, 1404, 1407-1408, 1410-1411, 1414-1415, 1422, 1424, 1433-1434, 1436, 1444, 1448, 1451, 1453, 1476, 1479, 1484-1485, 1488, 1494, 1496-1498, 1501, 1509, 1524-1526, 1528-1529, 1533, 1537, 1544, 1547, 1599-1629, 1642, 1649-1652, 1654-1656, 1695-1698, 1700, 1702, 1706, 1708, 1710-1713, 1715-1719, 1722-1723, 1727, 1730, 1736, 1740, 1743, 1746, 1750, 1752, 1754, 1758, 1762-1765, 1773, 1777, 1783, 1785, 1795-1796, 1801, 1810, 1815, 1818, 1827, 1829, 1836-1837, 1839, 1841, 1843, 1845, 1847-1849, 1852, 1856, 1861, 1873, 1875-1882, 1886, 1901, 1903, 1910-1911, 1913, 1915, 1917-1918, 1920-1921, 1923, 1927-1928, 1930-1931, 1935, 1937, 1939-1941, 1943-1944, 1947, 1951, 1955, 1957, 1973, 1975, 1996-2000, 2024, 2027-2028, 2030-2038, 2040, 2042, 2048-2050, 2075 |
PARTS NEEDED
Qty |
Part Number | Description |
1 | 4620514 | BOARD-CIRCUIT |
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
Remove all 266-5825 Circuit Boards from dealer parts stock. |
Image1 |
Refer to the attached Rework Procedure. |
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock. |
0-60 mo |
NOTE: This is a 1.0-hour job | ||||||
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
General Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect all shore power connections and disconnect battery cables. Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work. Only qualified repair personnel should service this equipment. CAUTION: Handle the Printed Circuit Board (PCB) carefully. Do not drop or flex the PCB. |
Step 1 ? Open the control panel door to gain access to the existing control panel circuit board. Step 2 ? Confirm that the existing control panel circuit board is the 266-5825 Circuit Board. The 266-5825 Circuit Board can be identified by inspecting the circuit board IC module manufacturer name (NGH) and the part number 650-091 labeled on the circuit board. Refer to Image 1.2.1. Image 1.2.1 (1) 266-5825 Circuit Board Identification; IC Module Manufacturer - NGH (2) 266-5825 Circuit Board Identification; Part Number 650-091 |
Image1.2.1 |
Step 3 ? Disconnect the four wire harness connectors from the existing control panel circuit board. There is a 24-pin connector and three single spade type connectors. The wiring configuration for the three single spade type connectors is as follows: Wire 68 connects to Circuit Board Terminal "ALM RESET" Wire 70 connects to Circuit Board Terminal "ALM" Wire 56 connects to Circuit Board Terminal "FLAP VALVE" Refer to Image 1.3.1. Step 4 ? Remove the retaining hardware from each corner of the existing control panel circuit board. Retain the hardware for reuse. Refer to Image 1.3.1. Image 1.3.1 (1) Wire harness connector; 24 Pin (2) Wire harness connector; Wire 56 (3) Wire Harness connector; Wire 68 and Wire 70 (4) Circuit Board retaining hardware |
Image1.3.1 |
Step 5 ? Install the new 462-0514 Circuit Board. Secure the PCB into position using the retaining hardware from Step 4. Note: The new 462-0514 Circuit Board can be identified by inspecting the circuit board IC module manufacturer name (IMO) and the part number 462-0514 labeled on the circuit board. Refer to Image 1.4.1. Image 1.4.1 (1) 462-0514 Circuit Board Identification; IC Module Manufacturer ? IMO (2) 462-0514 Circuit Board Identification; Part Number 462-0514 |
Image1.4.1 |
Step 6 ? Attach the wire harness connectors to the new 462-0514 Circuit Board. Step 7 ? Reconnect the Battery cables. Step 8 ? Perform a basic Crank, Start, Run functional test of the generator set. Step 9 ? Restore the alternator set to its proper operational readiness condition. Step 10 ? Task Complete |