Usage:
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.
NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4222" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
NOTE: This Program applies only to Generator Sets in the Affected Product Number Range that have EMCPII and are operating in parallel.
NOTE: This Revised Service Letter replaces the March 2, 1998 (Revised August 1998) Service Letter. Changes have been made to the Service Claim Allowances.
Termination Date
March 31, 1999Problem
Some generator set controls fail to trip the circuit breaker when an engine shut down is initiated by the ADEM II Engine Control on certain 3508B, 3512B and 3516B Engine Generator Sets equipped with an Electronic Modular Control Panel (EMCPII).
Affected Product
Model & Identification Number
3508B (4GM129-253 6PN162-343 )
3512B (6WN76-156 8RM113-247 )
3516B (6HN104-181 7RN210-507 )
Parts Needed
- 2 - 1G6420 Spring
- 70 - 7K1181 Strap
- 1 - 5N9072 Clip
- 1 - 5N9117 Adapter
- 3 - 5P1477 Terminal
- 40 - 5P5677 Wire (measured in decimeters)
- 2 - 9X9675 Bracket
- 1 - 625388 Locknut
- 4 - 1093038 Wire End
- 2 - 1157947 Relay
- 2 - 1157946 Socket
- 27 - 1471960 Rail (measured in centimeters)
- 1 - 1504491 Harness Assembly
- 6 - 1504492 Ring
- 70 - 7K1181 Strap
Action Required
See the attached rework procedure.
Service Claim Allowances
NOTE: This is a 2-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
A relay and wiring harness must be added to the generator set package to provide the proper communication between the ADEM II control and the generator status control (See Illustrations 1 and 2).
1. Install the relays and wiring as shown in Illustrations 1 and 2. The relays are to be installed in the generator terminal box.
2. Connect the wiring as shown in Illustration 1 and 2. Refer to Electrical Schematic RENR1242-02.
3. Using Cat ET, change the CRANK TERMINATE engine speed to 100 RPM (consult the CAT ET instruction manual for detailed instruction on how to accomplish this step.)
NOTE: This procedure directs the modification of the ADEM II crank terminate speed for the purposes of this rework program only.
4. Change the Spare Alarm Input #2 signal response and active state by using the following procedure outlined on pages 17 through 25 of the EMCP II Service Manual for EUI Engines, SENR5398:
- Enter the service mode on the EMCP II Generator Set Control as outlined in the Systems Operation section of the Service Manual, page 17.
- Select option 6 (OP6), Spare Input/Output Programming
- Program the Spare Input Response for Input #2 (SP02) for SHUTDOWN by entering a 0 (zero) for SP02 (see Service Manual)
- Program the Spare Input Active State for Input #2 (SP03) to an ACTIVE HIGH by entering a 1 (one) for SP03 (see Service Manual)
5. Ensure the crank terminate speed programmed in the GSC is set to 400 RPM (factory default) using the following procedure:
- While still in the service mode, scroll to option 5 (OP5).
- Within OP5, select SETPOINT P11, CRANK TERMINATE SPEED
- The value for this setpoint should be 400 RPM. Adjust if necessary by using the service manual procedure.
- Exit from the service mode following procedures in the EMCP II Service Manual.
Illustration 1
Illustration 2