PRODUCT SUPPORT PROGRAM FOR REPLACING THE METHANE DETECTOR ON CERTAIN PMG3516C (XQ1475G) POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE METHANE DETECTOR ON CERTAIN PMG3516C (XQ1475G) POWER MODULES

Usage:

TEBE4418-00

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26May2016

D35P
J520

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE METHANE DETECTOR ON CERTAIN PMG3516C (XQ1475G) POWER MODULES
0774		PS45087

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS45087" 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

31May2017

PROBLEM

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Methane detectors may fail due to high operating ambient temperature on certain PMG3516C (XQ1475G) Power Modules.

AFFECTED PRODUCT

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Model	Identification Number
PMG3516C	JKK00102-00105, 110-111, 113-115, 118, 122, 124, 126, 128, 131, 138-139, 145, 150-151, 158-159, 164-169, 171, 173, 175, 177-178, 182-183, 185, 188-189, 210

PARTS NEEDED

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Qty	Part Number	Description
2	8T8908	BOLT
762	1365321	CABLE-BULK (762 CM)
305	1514908	WIRE-ELECTRICAL (305 CM)
2	2013160	NUT-SPRING
1	4565076	CONT GP -B
1	4565077	DETECTOR GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% 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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Important Safety Information
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.
The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.
WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

Refer to the attached Rework Procedure.

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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%
0-10000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-15000 hrs, 61-72 mo	50.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 2.5-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.

Rework Procedure

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Remove existing methane detector and discard. Replace with new methane detector 456-5077 on existing mounting bracket (Image 1.1.1).

Image1.1.1

Install Methane Detector Controller inside switchgear on existing strut. (Image 1.2.1)

Image1.2.1

Wire newly installed methane detector and controller per diagram listed below (Image 1.3.1). Use existing conduit. Existing wire may be used. If new wires are needed use the following.
136-5321 cable 3 wire shielded approximately 25 feet (7.6 Meters) needed for installation of new detector. 151-4908 wire 18 gauge approximately 10 feet (3 Meters) needed for installation of new detector.

Image1.3.1

Testing and Calibration

For calibration

Use calibration gas tool 458-8181.
Refer to the Methane Detector Manual section 3.19 page 31 that is included with the new methane detector 456-5077.
Use calibration gas tool 458-8181. Note that this tool is enough to test approximately 20 units.

For testing
After calibration place the unit in Local Mode.
1.) Place the calibration tool on the sensor.
2.) Watch the % methane gas increase in value.
At 10%, DEIF Controller will display Gas Detected ? Shutdown
3.) Remove calibration tool.
4.) Reset shutdown signal.
5.) XQ1475 is now ready for service.

Completed layout (Image 1.4.1)