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 "PS4357" 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 Revised Service Letter replaces the June 21, 1998 Service Letter. Changes have been made to the Affected Product.
Termination Date
June 30, 1999Problem
Some 1182070 GSC+ (Generator Set Control+) Modules, change level 08 or earlier, used in the EMCP II+ control panels may have a microprocessor interupt which may result in shutting down the generator set. No fault code is logged for this problem. Improved software needs to be installed using the Caterpillar "ET" Service Tool.
Affected Product
Model & Identification Number
3208 (5YF3418, 5YF3419, 5YF3522, 5YF3524-3525, 5YF3729, 30A6801-6802, 30A7031, 30A7081, 30A7096, 30A7098, 30A7100-7101, 30A7142-7143)
3304 (83Z10194, 83Z10238, 83Z10244, 83Z10246, 83Z10284, 83Z10614)
3306B (9NR1614-1615, 9NR1619-1620, 9NR1622, 9NR1647, 9NR1651, 9NR1699, 9NR1730-1731, 9NR1852, 9NR1875, 9NR1909, 9NR1915, 9NR1926, 9NR1930, 9NR1935, 9NR1938-1939, 9NR1943, 9NR1951, 9NR2004, 9NR2006-2007, 9NR2009, 9NR2011, 9NR2027, 9NR2038-2039, 9NR2089, 9NR2106, 9NR2108, 9NR2158, 9NR2170, 9NR2174, 9NR2180, 9NR2216, 9NR2225, 9NR2310, 9NR2345, 9NR2354, 9NR2382, 9NR2396, 9NR2412, 9NR2421, 9NR2423-2324, 9NR2453, 9NR2456, 9NR2465, 9NR2489, 9NR2523, 9NR2529, 9NR2530-2533, 9NR2535-2536, 9NR2542, 9NR2586, 9DS388, 9DS418, 9DS433, 9DS458, 9DS471, 9DS504, 9DS506, 9DS511, 9DS526, 9DS535-536, 9DS568, 9DS695, 9DS726, 9DS739, 9DS753, 9DS756, 9DS778, 9DS785, 9DS839, 9DS841-843, 9DS849, 9DS851, 9DS875,9DS878, 1CZ189, 1CZ207, 1CZ248, 1CZ271, 1CZ303, 1CZ316, 1CZ400, 1CZ414-415, 1CZ434, 1CZ446, 1CZ467, 1CZ605, 1CZ608, 1CZ729, 1CZ735, 1CZ739-740, 1CZ933, 1CZ974)
3406C (4ZR2056-2058, 4ZR2126, 4ZR2300, 4ZR2302, 4ZR2323, 4ZR2346, 4ZR2351, 4ZR2354, 4ZR2356, 4ZR2375, 4ZR2405, 4ZR2416, 4ZR2418, 4ZR2436, 4ZR2441, 4ZR2443, 4ZR2447-2449, 4ZR2452, 4ZR2454, 4ZR2467, 4ZR2475-2476, 4ZR2499, 4ZR2503-2504, 4ZR2512-2514, 4ZR2526-2528, 4ZR2652, 4ZR2716, 4ZR2722-2723, 4ZR2736, 4ZR2792, 4ZR2809, 4ZR2817, 4ZR2819, 4ZR2823-2824, 4ZR2826-2827, 4ZR2836, 4ZR2842, 4ZR2846, 4ZR2855, 4ZR2859, 4ZR2877-2878, 4ZR2880-2881, 4ZR2892, 4ZR2916, 4ZR2951, 4ZR2955, 4ZR2964, 4ZR2997, 4ZR3024, 4ZR3060, 4ZR3080, 4ZR3090, 4ZR3105, 4ZR3120, 4ZR3130, 4ZR3138, 4ZR3145, 4ZR3158, 4ZR3188, 4ZR3212, 4ZR3221, 4ZR3232, 4ZR3234, 4ZR3241, 4ZR3246, 4ZR3251-3252, 4ZR3257, 4ZR3324, 4ZR3330, 4ZR3356, 4ZR3376, 4ZR3442-3443, 4ZR3457, 4ZR3475-3476, 4ZR3484-3486, 4ZR3490-3492, 4ZR3494-3497, 4ZR3514, 4ZR3547, 4ZR3550, 4ZR3560, 4ZR3606, 4ZR3611, 4ZR3615, 4ZR3623, 4ZR3637-3641, 4ZR3653, 4ZR3660, 4ZR3683, 4ZR3686, 4ZR3708, 1LS390, 1LS409-411, 1LS413-418, 1LS450-455, 1LS470, 1LS541, 1LS543-550, 8FS536, 8FS568, 8FS573, 8FS577, 8FS593, 8FS647, 8FS678, 8FS694, 8FS702, 8FS752, 8FS790, 8FS792, 8FS795, 8FS847, 8FS850, 8FS853-854, 8FS876, 8FS882, 8FS886, 8FS902, 8FS904, 8FS940, 8FS942, 8FS951, 8FS978, 8FS1011, 8FS1018, 8FS1026, 1DZ106-107, 1DZ152, 1DZ186, 1DZ196, 1DZ209, 1DZ211, 1DZ222, 1DZ239, 1DZ257, 1DZ266, 1DZ268, 1DZ315, 1DZ318, 1DZ427, 1DZ435, 1DZ470, 1DZ476, 1DZ479, 1DZ503, 1DZ522, 1DZ524, 1DZ527, 1DZ532, 1DZ556, 1DZ572, 1DZ575, 1DZ588, 1DZ937)
3412 (2WJ1082-1083, 2WJ1103-1104, 2WJ1129-1130, 2WJ1133, 2WJ1160, 2WJ1244-1245, 2WJ1250-1255, 2WJ1257-1258, 2WJ1275, 2WJ1279, 2WJ1281-1282, 2WJ1307-1309, 2WJ1321, 2WJ1325, 2WJ1340, 2WJ1354-1359, 2WJ1366, 2WJ1371, 2WJ1380, 2WJ1389-1390, 2WJ1400, 2WJ1410, 2WJ1412, 2WJ1442, 2WJ1448-1449, 2WJ1463, 2WJ1469, 2WJ1472-1473, 2WJ1499, 2WJ1501, 2WJ1561, 2WJ1573, 2WJ1575-1578, 2WJ1581, 2WJ1583, 2WJ1587, 2WJ1592, 2WJ1594, 2WJ1597, 2WJ1606, 2WJ1621, 2WJ1629, 2WJ1632, 2WJ1641-1642, 2WJ1679, 2WJ1681, 2WJ1686, 2WJ1705, 1EZ218, 1EZ233, 1EZ245, 1EZ249, 1EZ263, 1EZ289, 1EZ409-410, 1EZ417, 3FZ319, 3FZ330, 3FZ351, 3FZ467, 3FZ536, 3FZ566, 81Z20413, 81Z20562, 81Z20617, 81Z20660, 81Z20688-20700, 81Z20705, 81Z20710, 81Z20714-20715, 81Z20720, 81Z20790, 81Z20796, 81Z20798, 81Z20807, 81Z20820, 81Z20829, 81Z20863, 81Z20880, 81Z20891, 81Z20913, 81Z20971, 81Z20974, 81Z21011, 81Z21025, 81Z21032, 81Z21075, 81Z21093-21094, 81Z21129, 81Z21151, 81Z21161, 81Z21168, 81Z21179, 81Z21191-21192, 81Z21208, 81Z21219, 81Z21227, 81Z21229, 81Z21232, 81Z21297, 81Z21404, 81Z21408, 81Z21412, 81Z21419, 81Z21441, 81Z21482-21483, 81Z21532, 81Z21538, 81Z21562, 81Z21567, 81Z21573, 81Z21581, 81Z21619, 81Z21621, 81Z21675, 81Z21679, 81Z21696, 81Z21699, 81Z21712, 81Z21714, 81Z21730, 81Z21734, 81Z21748, 81Z21792, 81Z21827, 81Z21837, 81Z21879, 81Z21887, 81Z21901, 81Z21912, 81Z21917, 81Z21919, 81Z21922, 81Z21926, 81Z21928, 81Z21931, 81Z21937, 81Z21940-21941, 81Z21946, 81Z21964, 81Z21979, 81Z21988-21991, 81Z22028, 81Z22051, 81Z22062, 81Z22069, 81Z22072, 81Z22078, 81Z22081, 81Z22097, 81Z22112, 81Z22116, 81Z22204, 81Z22206, 81Z22246, 81Z21964, 81Z21979, 81Z21988-21991, 81Z22028, 81Z22051, 81Z22062, 81Z22069, 81Z22072, 81Z22078, 81Z22081, 81Z22097, 81Z22112, 81Z22116, 81Z22204, 81Z22206, 81Z22246, 81Z22278, 81Z22306, 81Z22309, 81Z22321, 81Z22351, 81Z22368, 81Z22395, 81Z22425)
3508 (3LS197, 1JZ132, 23Z6877, 23Z6914, 23Z6934-6935, 23Z6942, 23Z6952, 23Z6978, 23Z6985, 23Z6996, 23Z6998, 23Z7000, 23Z7021, 23Z7043, 23Z7048-7050, 23Z7067, 23Z7069-7072, 23Z7074-7075, 23Z7079, 23Z7089-7090, 23Z7096, 23Z7102, 23Z7114-7114, 23Z7149, 23Z7151, 23Z7180, 23Z7188)
3508B (4GM225, 4GM278, 4GM284, 4GM298, 6PN373, 6PN400, 6PN404, 1FZ150, 1FZ215, 1FZ221, 1FZ252)
3512 (, 6PM29, 1KZ124, 1KZ127, 1KZ129, 1KZ136, 1KZ139, 1KZ152, 1KZ159, 1KZ219, 1KZ231, 24Z7772, 24Z7913, 24Z7922, 24Z7948, 24Z7960, 24Z7975, 24Z8020, 24Z8029, 24Z8083, 24Z8130, 24Z8133, 24Z8138, 24Z8145, 24Z8148-8149, 24Z8154, 24Z8157, 24Z8162, 24Z8180, 24Z8215, 24Z8287, 24Z8300, 24Z8309, 24Z8312, 24Z8326, 24Z8366, 24Z8391-8392, 24Z8396, 24Z8398-8399, 24Z8401, 24Z8404, 24Z8407, 24Z8415, 24Z8445-8447, 24Z8450, 24Z8457, 24Z8459, 24Z8465-8466, 24Z8471-8472, 24Z8474, 24Z8478, 24Z8481, 24Z8484, 24Z8492, 24Z8503, 24Z8508, 24Z8529, 24Z8535, 24Z8551-8552, 24Z8561-8562, 24Z8565, 24Z8570, 24Z8573, 24Z8581-8582, 24Z8584, 24Z8588, 24Z8592, 24Z8614, 24Z8624-8625, 24Z8636, 24Z8656, 24Z8672, 24Z8682, 24Z8705, 67Z1454-1456, 67Z1495, 67Z1499)
3512B (6WN147-148, 6WN152, 6WN163, 6WN177-178, 6WN183, 6WN195, 1GZ142-143, 1GZ207)
G3512 (7NJ300)
3516 (5SJ545, 5SJ552, 5SJ554, 5SJ560-561, 5SJ601-602, 5SJ605-606, 5SJ612, 3NS214, 4XF688-689, 4XF704-706, 4XF712, 4XF717, 4XF721, 4XF723, 4XF731, 4XF733, 25Z5530, 25Z5552, 25Z5588, 25Z5592-5593, 25Z5598, 25Z5625, 25Z5629-5630, 25Z5634, 25Z5636, 25Z5641-5642, 25Z5669, 25Z5682, 25Z5700-5701, 25Z5703, 25Z5705-5709, 25Z5718, 25Z5720, 25Z5726, 25Z5731, 25Z5747, 25Z5749, 25Z5751, 25Z5776, 25Z5813, 25Z5819, 25Z5821, 25Z5824, 25Z5827-5828, 25Z5832-5833, 25Z5837, 25Z5839, 25Z5841, 25Z5847, 25Z5858, 25Z5860, 25Z5867, 25Z5873, 25Z5879-5881, 25Z5899, 25Z5903, 25Z5907, 25Z5960, 25Z6002, 25Z6017, 25Z6028, 25Z6038, 73Z800-801, 73Z814, 73Z818, 73Z861-862, 73Z)
3516B (6HN160-161, 6HN173-174, 6HN185, 6HN193, 6HN209, 6HN216-217, 6HN219, 6HN224, 7RN516-517, 7RN522-524, 7RN531, 7RN552, 7RN559, 7RN566-568, 1HZ139)
Parts Needed
Action Required
See the attached rework procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
Tools Needed
- 7X1701 - Caterpillar Communication Adapter
- 7X1425 - Cable Assembly (PC to Communication Adapter)
- 7X1570 - Cable Assembly (1394166 Cable Assembly may be used)
- 1527143 - GSC+ Data Adapter Cable (connects the Service Tool cable to EMCP II+ terminal strip using spades)
- - PC capable of running Caterpillar Electronic Technician (ET) software version 2.0 or later.
- 7X1425 - Cable Assembly (PC to Communication Adapter)
Connections for GSC+ mounted in an EMCP II+ panel with 24VDC power available to the panel
1. The GENSET must NOT be running. Also, turn power OFF to the EMCP II+ panel by disconnecting the battery negative from the electrical system.
2. Connect the communication adapter to the PC using the 7X1425 Cable. The metal Deutsch connector should be connected to the "Service Tool" port on the communication adapter.
3. Connect Caterpillar Service Tool Cable, 7X1570 or 1394166, to the "Control" port on the communication adapter.
4. Connect the GSC+ data adapter cable, 1527143, to the other end of the service tool cable.
5. Connect the spade terminals labeled Data+, Data- to the appropriate terminals in the Aux. terminal strip inside the EMCP II+ panel. Connect the Power+, and Power- spade terminals to RM1 and RM28 respectively of the relay module of the GSC+.
NOTE: For switchgear conversion systems containing the GSC+ control, the connection points for the Data+ and Data- wires are GSC-19 and GSC-20 respectively of the 40-pin connector on the GSC+. The spade terminals on the harness for these wires need to be replaced with two 8T8730 Sockets. After this rework has been completed, the modified portion of the harness can be removed from the 40-pin connector using a 1219588 Removal Tool.
6. Set the engine control switch (ECS) to OFF/RESET, connect the battery to the electrical system and then turn the ECS to the COOL-STOP position.
7. Verify that the GSC+ and the communication adapter are powered-on.
NOTE: Once the software update process has been started, power-loss to the GSC+ is unacceptable. The loss of power may render the GSC+ unusable.
8. Turn the PC on and wait for Windows to boot up.
Flash Update Procedure
1. Find the CatET directory using Windows File Manager and open it.
2. Start WinFlash by double-clicking on the WinFlash icon using the mouse pointer (WinFlash is part of the CatET software package).
3. After start-up is complete, CatET will automatically try to connect to the GSC+ through the Communication Adapter.
4. The WinFlash program will display the serial numbers of any modules found on the datalink.
5. Select the serial number of the unit you want to update and click on "OK". The serial number of the desired GSC+ can be obtained by looking at the first value under OP2-2 in service mode. This can be achieved by pressing the service mode key on the GSC+ once, then pressing the "SCROLL UP" key (also the LAMP-TEST key) once. All GSC+ units have a serial number suffix of "HA". This can be used for verification.
6. Click on the "select file" button, open the floppy drive (it is the A-drive in most computers) and select the appropriate .fls file. This flash file is labeled 16333480.fls.
7. If the genset has an energized-to-run (ETR) fuel solenoid, skip this step and go to the next step. If the genset has an energized-to-shutdown (ETS) fuel solenoid, wait for at least 70 seconds before going to the next step.
8. Click on the "Begin" button and the flash process should begin with a progress bar showing on the PC.
NOTE: Once the software update process is started, power loss to the OSC+ is unacceptable. Loss of power may render the GSC+ unusable. Make sure that power will be available for the few minutes that the flash process will require. If the flash process is aborted, do not remove power from the GSC+ until programming has been restarted and completed.
9. The GSC+ display will be blank with the "Fault Shutdown" indicator blinking while the software update is in progress.
10. Don't disturb the process while waiting for it to complete. Once completed, the GSC+ will automatically start working again. Exit the WinFlash software.
11. The GSC+ should now have the new software. This update will not affect the setpoints or calibration.
12. Turn the engine control switch (ECS) back to OFF-RESET and disconnect the battery from the electrical system. Disconnect the service cables and close the panel.
13. Reconnect the battery to the electrical system and return the genset to service.