PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SPACER (PLATE) WITHIN THE LOAD BOARD ASSEMBLY ON CERTAIN PMC27 (XQ800) GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SPACER (PLATE) WITHIN THE LOAD BOARD ASSEMBLY ON CERTAIN PMC27 (XQ800) GENERATOR SETS

Usage:

TEBE4947-02

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12Jul2016

(Revised 31Mar2017)

U-366

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SPACER (PLATE) WITHIN THE LOAD BOARD ASSEMBLY ON CERTAIN PMC27 (XQ800) GENERATOR SETS
1418 7426 4460		PI32661

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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 as soon as possible. When reporting the repair, use "PI32661" 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 "PI32661" as the Part Number, "7751" as the Group Number, "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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NOTE:	This Revised Service Letter replaces the 12Jul2016 (Revised 11Oct2016) Service Letter. Changes have been made to the Action Required and Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31Jan2017	31Jul2017

PROBLEM

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On certain PMC27 (XQ800) Generator Sets, the load board assembly may not seat properly when placed in the high position (480 V) due to an incorrect glastic spacer (plate). The thickness of the spacer may cause a gap between the other bus bars when placed in position. Replacement of the spacer will be required.

AFFECTED PRODUCT

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Model	Identification Number
PMC27	N1B00100-00105, 107-149, 151-158, 161-224, 228-253, 261-273, 278-292, 297-337, 340-345, 370-371

PARTS NEEDED

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Qty	Part Number	Description
1	SPACER	SPACER (Refer to Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 mechanically and electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against unintended operation and the unexpected movement, 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.

Action Required

The spacer should have already been provided to the dealer. If a dealer does not have the parts, have the Dealer Technical Communicator (TC) submit a request for the parts to CPI number 372183 through CPI Feedback within the Service Information Management System (SIMSi).

On certain PMC27 (XQ800) Generator Sets, the load board assembly (1) may not seat properly when placed in the high position (480V) due to an incorrect glastic spacer (2) within the load board assembly.

The thickness of the spacer (3) may cause a gap between the other bus bars when placed in position. Replacement of the spacer (3) will be required. Refer to Image1, Image2, and Image3.

Refer to the attached Rework Procedure.

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Image1

Image2

Image3

OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SPACER (PLATE) WITHIN THE LOAD BOARD ASSEMBLY

MODELS INVOLVED - CERTAIN PMC27 (XQ800) GENERATOR SETS

Dear Cat Product Owner:

The spacer within the load board assembly needs to be replaced on the products listed below. The existing spacer may cause a gap between the other bus bars which may lead to bus bar over-heating and deterioration. You will not be charged for the service performed.

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

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 12Jul2016 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 12Jul2016 Service Letter

Rework Procedure

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Ensure battery isolation switch is in the OFF position and lockout/tagout procedures have been applied.

Open change-over board door and remove the quantity 10 nuts and washers holding the top (moveable) board from the change-over board assembly. Refer to Image1.2.1.

Image1.1.1

Using a 7/16" wrench and screwdriver, remove the quantity 2 fasteners holding the existing spacer from the top board assembly. Refer to Image1.3.1

Image1.2.1

Install the new SPACER in the same location as the orignal spacer with the flat side of the spacer against the top board surface. Align the large hole of the new SPACER with the large hole of the change-over board. Tighten the fastners to 12 +/-3 Nm. Refer to Image1.4.1 and Image1.4.2.

Image1.3.1

Image1.3.2

Re-install the updated top board assembly to the base of the change-over board in the low voltage position. Tighten the quantity 10 nuts to 105 +/- 20 Nm. Close the change-over board door. Refer to Image1.5.1. Remove the lockout/tagout provisions of the battery isolation switch.

Image1.4.1

Close the battery isolation switch and press the AC Overview button on the EMCP face. Scroll down to the bottom screen and confirm that the rated voltage is 240 or 208. Note: This value would depend on the position of the voltage/frequency selector switch inside the control panel.

If the rated voltage is not displaying the correct value, turn Off the battery isolation switch and confirm the step portion of the new SPACER is pressing on the 4 push button switches mounted on the change-over board base when the top board is in the low voltage position.

After confirming the low voltage position is functioning correctly, turn Off the battery isolation switch and place the top board assembly in the high voltage position.

Close the battery isolation switch and press the AC Overview button on the EMCP face. Scroll down to the bottom screen and confirm that the rated voltage is 480 or 400. Note: this value would depend on the position of the voltage/frequency selector switch inside the control panel.

Once all board positions are functioning correctly, place the top board in the desired operating position for the package and return to service.