PRODUCT SUPPORT PROGRAM FOR REPLACING THE AC SENSING HARNESS ON CERTAIN C15 AND C18 GENERATOR SETS
Usage:
REBE8744-00
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| 18Oct2012 |
O-504
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| After Failure Only | PRODUCT SUPPORT PROGRAM FOR REPLACING THE AC SENSING HARNESS ON CERTAIN C15 AND C18 GENERATOR SETS |
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| 4476 1408 | PS52314 |
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| 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 "PS52314" 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. |
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| 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. |
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TERMINATION DATE |
| 31Oct2014 |
PROBLEM
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| Certain C15 and C18 Generator Sets may have incorrect current transformer (CT) wiring. This issue was on the Electronic Modular Control Panel (EMCP) 4.2 which causes the KW to be displayed as a negative value and also a Reverse Power Shutdown occurs. The wiring was incorrect on all panels but is not noticeable on the EMCP 4.1 as they do not display KW and do not contain the Reverse Power Shutdown. Therefore, it is not critical for the EMCP 4.1 as they will function as normal. But if future control panel upgrades are required, this wiring should be corrected. Therefore it is recommended this rework should be performed where possible. |
AFFECTED PRODUCT
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| Model | Identification Number |
| C15 | LNA00123-00160, 165-167 |
| C18 | LNB00123-00161, 175 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 4 | 1S9593 | STRAP-CABLE |
| 1 | 3981563 | HARNESS AS |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 8% 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
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| Refer to the attached Rework Procedure. |
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SERVICE CLAIM ALLOWANCES
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0-12 mo |
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| NOTE: This is a 0.5-hour job | ||||||
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PARTS DISPOSITION
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| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
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| If the wiring at the 6 way plug in the CT block is incorrect the 398-1563 Harness Assembly should be replaced. The correct wiring should be: Terminal 1 : C10 Terminal 2 : C30 Terminal 3 : C50 Terminal 4 : C90 Terminal 5 : C90 Terminal 6 : C90 Note: The terminal numbers are stamped into the back of the 6 way plug |
| REMOVAL OF AC SENSING HARNESS |
| 1. Ensure that the generator set has been safely isolated from starting. |
| 2. Remove the generator cover to allow access the AC sensing harness. See Image 1.4.1. |
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| Image1.4.1 |
| 3. Cut and remove any cable straps that secure the AC sensing harness onto the winding cables. |
| 4. Remove the 6 way plug from the CT block. |
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| Image1.6.1 |
| 5. Disconnect the 37 way plug from the socket. See Image 1.7.1. |
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| Image1.7.1 |
| 6. Loosen the 8 x M10 bolts and nuts then remove and retain the 4 bolts and nuts marked in Image 1.8.1 then remove the 4 sensing wires (101, 102, 103 and 104). |
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| Image1.8.1 |
| 7. If fitted, remove the connections from the Droop CT. See Image 1.9.1. |
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| Image1.9.1 |
| 8. Remove the 37 way socket by removing and retaining the 4 plastic snap rivets. The rivets are removed by pulling on the head of the rivet. See Image 1.10.1. |
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| Image1.10.1 |
| The AC sensing harness can now be removed. |
| FITTING OF REPLACEMENT AC SENSING HARNESS |
| 1. Fit the 37 way socket and replace the 4 plastic snap rivets. The rivets are installed by placing the rivet in the hole and press on the head of the rivet. See Image 1.13.1. |
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| Image1.13.1 |
| 2. Replace Voltage sensing wires (101, 102, 103, 104) and the 4 x M10 bolts and nuts. Ensure the wiring is correct when replacing the sensing wires. See Image 1.14.1. |
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| Image1.14.1 |
| 3. Ensure the ring crimps on the voltage sensing wires are located between the rectangular plate and copper busbar as shown in Image 1.15.1. |
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| Image1.15.1 |
| 4. Tighten all 8 x M10 bolts to 30Nm. See Image 1.16.1. When tightening and the bolts, ensure that the ring crimps do not rotate and become trapped underneath the copper. |
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| Image1.16.1 |
| 5. If the droop CT was originally fitted, replace the connections onto the Droop CT. (S1 and S2) See Image 1.17.1. |
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| Image1.17.1 |
| 6. Replace the 6 way plug into the CT block. Ensure the plug is pushed firmly into the CT socket. See Image 1.18.1. |
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| Image1.18.1 |
| 7. Secure any loose wires of the AC sensing harness with 1S-9593 Cable Straps. |
| 8. Reconnect the 37 way plug into the socket. See Image 1.20.1. |
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| Image1.20.1 |
| Once the work has been completed, the generator cover can be replaced. |
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