PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND/OR ITS MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60HZ GENRATOR SETS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND/OR ITS MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60HZ GENRATOR SETS

Usage:

REBE2160-00

10Aug2007


U-393
O-350

 
Priority
  
  

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND/OR ITS MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60HZ GENRATOR SETS

7940 1926 1901 1408
PI31324
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31324" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI31324" as the Part Number, "7751" as the Group Number, "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.


COMPLETION DATE

TERMINATION DATE

29Feb2008 31Aug2008

PROBLEM

The features codes for these parts were recently added to the price list, but the corresponding part numbers did not translate to the order. The component parts consist for each corresponding group should be ordered and installed on the unit as soon as possible.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
3516B PBR00344-00350, 358-362, 365, 368-369, 375

ZAP00603-00604
3516C  SBJ00250-00251, 255, 270, 278, 283, 287, 307
*******Group  2*******
3516C  SBJ00289
*******Group  3*******
3516B  PBR00376, 381
*******Group  4*******
3516B  PBR00382-00383
3516C  SBJ00256, 280

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 2340275 CONTROL AS
*******Group 2*******
2 2340275 CONTROL AS
*******Group 3*******
13 5C2890 NUT-HEX
6 5C9553 BOLT
7 6V7357 BOLT
12 9X6772 STRAP-CABLE
26 9X8256 WASHER
1 0975921 RAIL-MTG
5 1566175 CLIP-LADDER
2 1620589 BRACKET-END
20 1922925 BLOCK-TERMINAL
1 1922926 TERMINAL-COVER
1 2340275 CONTROL AS
1 2449601 HARNESS AS.
1 2449606 HARNESS AS
1 2449630 MARKER KIT
*******Group 4*******
13 5C2890 NUT-HEX
6 5C9553 BOLT
7 6V7357 BOLT
12 9X6772 STRAP-CABLE
26 9X8256 WASHER
1 0975921 RAIL-MTG
5 1566175 CLIP-LADDER
2 1620589 BRACKET-END
20 1922925 BLOCK-TERMINAL
1 1922926 TERMINAL-COVER
2 2340275 CONTROL AS
1 2449601 HARNESS AS.
1 2449606 HARNESS AS
1 2449630 MARKER KIT

ACTION REQUIRED

Refer to the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.0-hour job for Group 1

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.0-hour job for Group 2

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
100%
100%
0%
0%
0%
0%
 NOTE: This is a 4.0-hour job for Group 3

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
100%
100%
0%
0%
0%
0%

 NOTE: This is a 4.0-hour job for Group 4


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING DISCRETE I/O MODULES AND MOUNTING GROUP ON CERTAIN 3516B AND 3516C 60Hz GENRATOR SETS

MODELS INVOLVED - Certain 3516B and 3516C 60Hz Generator Sets

Dear Caterpillar Product Owner:

The Discrete I/O Modules and/or its Mounting Group needs to be installed on the products listed below. These parts were ordered, but were not included with the shipment. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 10Aug2007 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.



Caterpillar Inc.

Identification #(s)



Attached to 10Aug2007 Service Letter


Rework Procedure


Group Number 1   Group Number 2  
 
Order parts as specified in Parts Needed. Consolidate parts with "ship loose material" for customer order.
 
 
Group Number 3   Group Number 4  
 
1) Bolt Control As. 234-0275 to generator housing using (4) 5C-9553 bolts, (8) 9X-8256 washers and (4) 5C-2890 hex nuts as show in image 2.1.1.

Note: There may be an RTD module, which looks almost identical to the I/O module (but different label) installed in this location. If there is, install I/O module in the location directly below this location.
Image2.1.1
 
2) Connect Wiring Harness 244-9606 to the 234-0275 Control Assembly. Secure harness in place by installing the 156-6175 ladder clips and using the 6V-7357 bolt and 9X-8256 washer to hold it in place. Secure the harness to the 156-6175 ladder clips with the 9X-6772 tie straps as shown in images 2.2.1; 2.2.2; 2.2.3.

Run opposite end of harness through housing to the AC/DC control box (see images 2.2.4; 2.2.5 & 2.2.6).
Image2.2.1
Image2.2.2
Image2.2.3
Image2.2.4
Image2.2.5
Image2.2.6
 
3) Install the 244-9601 harness between the voltage regulator and the 234-0275 control assembly. Secure harness in place by installing (3) 156-6175 ladder clips and using the (3) 6V-7357 bolts, (6) 9X-8256 washers and (3) 5C-2890 hex nuts. Secure the harness to the clip with the 9X-6772 tie straps as shown in image 2.3.1

Note: To further secure the harness, hold harness in place by attaching it to the other harnesses within the housing using the 9X-6772 tie straps as shown in image 2.3.2.

Also use electrical tape to protect the harness at the location shown in image 2.2.4
Image2.3.1
Image2.3.2
 
4) Assemble (1) 097-5921 Rail, (20) 192-2925 Terminal Blocks, (2) 162-0589 Bracket Ends, (1) 192-2926 Terminal Cover, (1) 244-9630 Marker Kit as shown in image 2.4.1
Image2.4.1
 
5) Land wires from the 244-9606 harness to the terminal strip (as shown in image 2.4.1). Use table in image 2.5.1 for guidiance
Image2.5.1
 
6) Install block group in the space provided within the AC/DC control box, using (2) 5C-9553 bolts, (4) 9X-8256 washers and (2) 5C-2890 hex nuts. See image 2.6.1 for illustration
Image2.6.1
 
7) Generator sets in group 4 include a spare 234-0275 control assembly. Include the spare 234-0275 control assembly with consolidated loose parts for customer order.
 
 

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