NHTSA ID Number: 10172453
Manufacturer Communication Number: TSB190225-021920
TSB/Document Date: 2020-03-16
Summary
This Technical Service Bulletin describes the verification and resolution to an issue that arises when a C100D2RE generator set is attempted to parallel with a C150, C200 or C275 generator set. When this occurs the B+ on the two units short with each other and the temperature of the paralleling cable rises. This is an update to a previously submitted communication.
2/21/2020
Campaign #4035: Fix for C100D2RE Generator Set Paralleling Control Wiring Issue
Technical Service Bulletin
Technical Service Bulletin: TSB190225
Released Date: 19-Feb-2020
Campaign #4035: Fix for C100D2RE Generator Set Paralleling Control Wiring Issue
Campaign #4035: Fix for C100D2RE Generator Set
Paralleling Control Wiring Issue
Warranty Statement
The information in this document authorizes specific changes to the repair practice for failures
covered under product warranty coverages.
Contents
Product Affected
C100D2RE
Issue
When a C100D2RE generator set is attempted to parallel with a C150, C200 or C275 generator
set, the B+ (24 VDC) on the two units short with each other, as a result of which the units cannot
be paralleled, and temperature of the paralleling cable rises.
Root Cause:
Due to a design error in C100D2RE generator set harness, paralleling C100 with any other
models causes the B+ (24 VDC) from one unit to be shorted to B+ on the other unit
Verification/Confirmation
Confirm if the unit has this issue by checking in the list of affected generator set serial numbers.
See Table 2.
Resolution
On the harness of C100D2RE (PN: A054R546) shown in Figure 1 below:
1. Swap P70-A and P70-B
2. Swap J40-1 and J40-2
Service Instructions
Follow all the necessary safety procedures along with Lock Out Tag Out.
On the harness of C100D2RE (PN: A054R546) shown in Figure 1 below:
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Campaign #4035: Fix for C100D2RE Generator Set Paralleling Control Wiring Issue
1. Swap P70-A and P70-B
2. Swap J40-1 and J40-2
The harness is in the front panel inside the top rack of generator set. To locate connectors P70 and
J40 with respect to the harness, refer to Figure 2.
Figure 1, Harness A054R546 with P70 and J40 highlighted
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Campaign #4035: Fix for C100D2RE Generator Set Paralleling Control Wiring Issue
Figure 2, Location of connectors P70 and J40 on harness
1. Swapping connections of P70 connector (PN: 0323-1637) requires a Terminal Remover tool
(refer to Figure 4 for examples) to remove the wires and reconnect them in the right location.
Unplug the side clip on P70 connector as shown in Figure 3, before inserting the tool to remove
wire connectors.
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Campaign #4035: Fix for C100D2RE Generator Set Paralleling Control Wiring Issue
Figure 3, P70 Connector
Figure 4, Terminal Remover Tools
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Campaign #4035: Fix for C100D2RE Generator Set Paralleling Control Wiring Issue
2. J40 connector is a Deutsch connector (PN: 0323-2334) and the wires (size: 16 AWG) can be
removed by removing the wedge (PN: 0323-2333) with a picker (refer to figure 5) and repositioning
the wires in the right location.
Figure 5, Picker to Remove Wedge
Confirm the fix performed above by checking for continuity on the terminals between harnesses
A054R544 (Figure 6) and A054R546 (Figure 1) indicated in Table 1, by using a multimeter.
Note : The reworked connectors should be plugged back and battery switch should be
in the OFF position to check for continuity.
Table 1, Terminals and resistance values to be checked for continuity on harnesses
A054R544 and A054R546
S. No.
Resistance value required
to indicate continuity
1
From J66A-12 to K23A-1
0 -1 ohm
2
From J66A-13 to K23A-2
0 -1 ohm
3
From TB3-5 to K20A-2
0 -1 ohm
4
From TB3-11 to K20-14
10k ohm
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Campaign #4035: Fix for C100D2RE Generator Set Paralleling Control Wiring Issue
Figure 6, Harness A054R544 showing location of connectors J66A and TB3
After the resolution is applied, put a green dot on J40 and P70 connectors as well as on the master
label for A054R546 with a permanent marker. If the fix is done in-house, add an extra green dot on
the shipping box. This will help identify repaired units and avoid misconnecting in future.
Campaign details:
Authorization number: 4035
Account code: 6
Travel: One trip allowed
SRTs:
00-902 – administrative time – 0.7
99-999 – Install parallel wire ins – 0.3
Fail code: PR-WH-MR
Expiration date: December 12, 2021
Table 2, List of Affected Serial Numbers
A180287414
A180288358
A180300973
A180300973
A180307780
A180307781
A180307781
A180311216
A180311217
A180313643
A180313644
A180313644
A180316108
A180316108
A190470269
A190470271
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Table 2, List of Affected Serial Numbers
A190472904
A190472942
A190473300
A190474502
A190474503
A190474520
A190474940
A190474980
A190479021
A190483031
A190486483
A190486485
A190488255
A190488256
A190488274
A190488772
A190488831
A190489344
A190489345
A190489351
A190489352
A190489353
A190490695
A190493435
A190500492
B180316609
B180316645
B180318731
B180318732
B190501278
B190501279
B190502108
B190502233
B190506462
B190507252
B190507453
B190507472
B190508153
B190508286
B190509731
B190512632
B190512651
B190515225
B190515678
B190515698
B190516157
C180332369
C180336449
C180336449
C180339323
C180339323
C180341659
C180341907
C180342405
C180345016
C180345225
C180345225
C180345664
C190518791
C190518812
C190519115
C190519131
C190519132
C190519831
C190519861
C190530071
C190530791
C190531987
C190532273
C190532311
C190533114
C190536207
C190536272
C190536291
C190537174
C190537959
C190537960
C190538325
C190538415
D180348999
D180350622
D180350622
D180350927
D180350927
D180351229
D180351229
D180351653
D180351653
D180352859
D180352859
D180353590
D180353591
D180353591
D180353593
D180353835
D180353953
D180353953
D180353955
D180353955
D180353955
D180354191
D180354305
D180354305
D180354711
D180354712
D190540193
D190540194
D190540194
D190540751
D190541688
D190542310
D190542314
D190545552
D190545553
D190547128
D190547458
D190548292
D190548311
D190549113
D190549131
D190549340
D190549371
D190549372
D190552810
D190552812
D190552831
D190553160
D190553161
D190553295
D190554332
D190554436
D190554473
D190554637
D190557749
D190557752
D190558064
D190559580
D190559631
E180357326
E180357721
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Table 2, List of Affected Serial Numbers
E180357885
E180360471
E180360471
E180360473
E180360474
E180360719
E180360720
E180360720
E180361193
E180361193
E180361194
E180361195
E180361195
E180361234
E180363667
E180363668
E180363905
E180364314
E180364315
E180368942
E180368942
E180368943
E180368943
E180369729
E190559736
E190560539
E190560720
E190562176
E190562213
E190562214
E190562231
E190562357
E190562567
E190562807
E190562873
E190564244
E190564245
E190564852
E190564853
E190564854
E190564856
E190564857
E190565145
E190565732
E190566314
E190569452
E190569512
E190569513
E190570233
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TSB/Document ID: TSB190225-021920
Replacement Service Bulletin Number:
MFR Communication Date: 2020-02-19
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:WIRING
MFR Component System:
MFR Component Subsystem:
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