PRODUCT SUPPORT PROGRAM FOR REWORKING THE CONTROL PANELS RUN, STOP, AUTO SWITCH ON CERTAIN C2.2 (MODEL XQ20) GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CONTROL PANELS RUN, STOP, AUTO SWITCH ON CERTAIN C2.2 (MODEL XQ20) GENERATOR SETS

Usage:

REBE5810-00

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15Sep2010

U-373

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CONTROL PANELS RUN, STOP, AUTO SWITCH ON CERTAIN C2.2 (MODEL XQ20) GENERATOR SETS
1420 4461 7451 4490		PS43160

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43160" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "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

30Sep2011

PROBLEM

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The shunt trip can cause the main circuit breaker to open when the genset has stopped in the AUTO position on certain C2.2 (Model XQ20) Generator Sets. This is because the current design has a DC supply to the shunt trip in the auto position, the protection relays (overload relay and under voltage timer) operate from the genset's AC supply. These are fail-safe units, so when they are not powered they default to the fault position. When the units are in the OFF position, the power to the shunt trip is removed so the breaker does not open.

AFFECTED PRODUCT

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Model	Identification Number
C2.2	GBE00108-00122, 133-142, 149-152, 161, 191, 215-219, 221-225, 235, 277, 284, 350-356

PARTS NEEDED

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Qty	Part Number	Description
24	8L8413	STRAP-CABLE
160	8T7875	WIRE (A TOTAL OF 160 CM IS REQUIRED)
1	1364877	SPLICE-WIRE
2	2401407	TERMINAL-FORK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% 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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1. Isolate the genset before commencing any work on the unit: open the genset breaker, activate the emergency stop, disconnect the auxiliary power supply for the battery charger and heaters, and disconnect the battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed. Lock out generator before commencing any type of work.

2. Remove wire 7 connection to overload unit terminal 95, insulate with 136-4877 Wire Splice and tie-back wire with 8L-8413 Cable Straps.

3. Add wire 8 (using 160 CM of the 8T-7875 Wire) and connect from overload unit terminal 95 to wire 8 connection at auto/run/stop switch. Refer to Image 1. Secure the wire and 240-1407 Fork Terminals using 8L-8413 Cable Straps to add the wire to the panel harness.

4. Clear the genset area, reconnect the batteries and release the emergency stop.

5. Run functional test on the genset.

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Image1

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-1000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-2000 hrs, 13-24 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%