PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE HARNESS ON CERTAIN C7.1 (XQ200) GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE HARNESS ON CERTAIN C7.1 (XQ200) GENERATOR SETS

Usage:

TEBE4596-02

Show/hide table

21Jun2016

(Revised 30May2018)

U-322

Show/hide table

After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE HARNESS ON CERTAIN C7.1 (XQ200) GENERATOR SETS
1403		PS53239

Show/hide table

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 can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS53239" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table


NOTE:	This Revised Service Letter replaces the 21Jun2016 (Revised 08Sep2016) Service Letter. Changes have been made to the Termination Date and Affected Product.

Show/hide table

TERMINATION DATE

31Dec2018

PROBLEM

Show/hide table

The existing engine harness can fail pin number 2 at bulkhead connector that provides power to control on certain C7.1 (XQ200) Generator Sets.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
C7.1	MRP00100-00127, 129-583, 603-627, 629-791, 796-806

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
4	3E4304	INSERT-THREADED
1	4977849	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

Show/hide table

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.

Refer to the attached Rework Procedure.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-5000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 2.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

The following steps detail the field replacement of the engine harness.

1. 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.

2. Locate and open the control Image 1.3.1 and Image 1.3.2.

Image1.3.1

Image1.3.2

3. Locate the glow plug relay, lift pump relay, ARD pump relay and the starter motor relay Image 1.4.1.

4. Remove the glow plug relay, starter motor relay, lift pump relay and ARD pump relay from the mounting chassis to the right of the voltage regulator. Save the relays and fasteners to be reused later.

Image1.4.1

5. Mounting Chassis Harness now needs to be reworked.

Wire C+ running from DC Socket Pin 3 located on the bulkhead wall in the back of the control panel to Splice C+ needs to be cut at the splice. The cut end from the splice wire C+ then is routed to MCB 1 bottom, this is a 16 A breaker Image 1.5.1. and Image 1.5.2 This will parallel socket pins 2 & 3 to share current.

Splice C+ and the four circuits feeding the GPR, SMR, LPR and APR relays should now be removed from the harness. This leaves circuits B+, 346, 17, 10, 330, 58A, 51, 20, 300, E+, 7A and 80 unused. The terminals on the end should be snipped off and the ends covered with heat shrink individually.

Image1.5.1

Image1.5.2

6. Remove generator side plate 425-1137. Drill four pilot holes with a diameter of 10.00 mm, shown on drawing in Image 1.6.1. Then install 4 M6 insert nuts 3E-4304.

Image1.6.1

7. This will be the mounting location for the relocated relays. Hardware shall be reused. Relays are installed in the order of APR, GPR, LPR and SMR. Image 1.7.1.