PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE SCHNEIDER ELECTRIC AND SQUARE D BRANDED MASTERPACT NW CIRCUIT BREAKERS (800 AMPS TO 6300 AMPS), INSTALLED ON CERTAIN C27, C32, 3512, 3512B, 3512C, 3516, 3516B, 3516C, 3516 Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE SCHNEIDER ELECTRIC AND SQUARE D BRANDED MASTERPACT NW CIRCUIT BREAKERS (800 AMPS TO 6300 AMPS), INSTALLED ON CERTAIN C27, C32, 3512, 3512B, 3512C, 3516, 3516B, 3516C, 3516

Usage:

TEBE8025-01

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31Jul2018

(Revised 08Aug2018)

U-448

A-331

D-395

O-401

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE SCHNEIDER ELECTRIC AND SQUARE D BRANDED MASTERPACT NW CIRCUIT BREAKERS (800 AMPS TO 6300 AMPS), INSTALLED ON CERTAIN C27, C32, 3512, 3512B, 3512C, 3516, 3516B, 3516C, 3516E, C175-16, G3512, G3512H, G3516B, G3516C, AND G3516H GENERATOR SETS
1420 4461		PI11154

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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 "PI11154" 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 "PI11154" 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:	This Revised Service Letter replaces the 31Jul2018 Service Letter. Changes have been made to the Action Required, Example Copy Of Owner Notification, and Rework Procedure.

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PROBLEM

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A nonconforming internal circuit breaker component may affect the electrical protection capability of the circuit breaker. If the circuit breaker has the nonconforming internal component, it is possible that all poles on the circuit breaker may not open if the circuit breaker is called upon to interrupt current (trip), or if the circuit breaker is manually switched to the off position. If a circuit breaker pole/phase does not open, this may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3512	LY700114, 116, 123, 145-147, 150, 154, 162, 164, 171-172
3512B	LY800145, 147, 227-228, 231, 242, 247-249, 251-252, 310, 317-319
3512B HD	LY900108
3512C	LYH00143-00144, 156-157, 163, 166, 171-172, 182, 193, 197, 200-201, 203, 208-210, 216-217, 221, 227, 236, 238, 248, 252, 255, 264, 270, 277
3512C HD	LYP00104-00106, 108, 112, 118-119, 121-122, 134-135
3516	YAS01002-01005, 1014-1015, 1017-1022
3516B	LY300102 YAT01003-01004, 1006-1008, 1020-1022, 1029, 1035, 1082-1084, 1090-1092, 1094-1096 YAW01001-01004, 1029
3516C	AL200149-00156 LY500112-00113, 118 SBJ02013, 2016-2018, 2025, 2029, 2046, 2049, 2051, 2072, 2098-2099, 2112-2114, 2124, 2127, 2130-2131, 2133, 2138-2140, 2146-2147, 2155, 2158, 2161, 2168, 2171, 2174, 2183-2184, 2204, 2210, 2213 SBK02007-02008, 2014-2021, 2023, 2025, 2027, 2029, 2031, 2033, 2053, 2059-2060, 2065, 2067, 2071, 2073, 2079, 2083-2084, 2086-2087, 2089, 2097, 2099, 2101, 2110-2111, 2114, 2131, 2135-2140, 2147, 2154-2155, 2158, 2160-2165, 2167-2168, 2170-2172, 2176-2200, 2204, 2209-2210, 2212-2227, 2249, 2257, 2260, 2273-2279, 2281, 2283-2285, 2288-2289, 2291, 2293-2297, 2299-2307, 2309-2314, 2317-2318, 2320, 2322-2324, 2326-2328, 2330-2333, 2335-2339, 2341, 2343-2348, 2350, 2352, 2354, 2356, 2358-2361, 2364, 2367-2369, 2372, 2374-2375, 2377-2378, 2380, 2383, 2388, 2392, 2394-2398, 2400, 2405, 2407-2429, 2434-2435, 2437-2439, 2441, 2444, 2448-2452, 2461-2462, 2473-2474, 2481, 2488-2489, 2491, 2496, 2508-2509, 2511-2512, 2514-2517, 2519, 2522-2527, 2529-2536, 2539-2542, 2563, 2573, 2575, 2589-2590, 2592, 2597, 2600, 2607-2611, 2614-2616, 2618, 2622-2623, 2626-2630, 2632, 2634-2655, 2658-2659, 2661-2666, 2668-2673, 2675-2683, 2685-2695, 2697-2700, 2702, 2705, 2708, 2712-2713, 2715, 2717-2718, 2721, 2723-2724, 2726-2739, 2741-2745, 2747-2749, 2751-2753, 2755-2756, 2761, 2763, 2765, 2767-2795 SCJ01002, 1005
C175-16	WYB01982-01986, 1988, 1990-1992, 2024-2025, 2131, 2152-2153, 2178, 2180, 2188, 2191
G3512	E2P00176, 178-179, 187-188 E2X00125, 127-129, 132-133
G3512H	GF500133
G3516B	ZBC01003-01004
G3516C	F6D00135-00136
G3516H	NWJ00103

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*****Group 2*****
C27	2A300154, 156, 181, 289, 298, 328, 332, 334-335, 429
C32	JAZ03333, 3348, 3354, 3370, 3378, 3397-3401, 3468-3469, 3479, 3489-3490, 3493, 3495 JSJ03070, 3089, 3100-3101, 3115, 3117, 3121, 3128, 3131, 3145, 3175-3177, 3191, 3217-3218, 3225, 3259, 3261-3263, 3266, 3299-3301, 3318-3319, 3368-3369, 3372-3373, 3377-3378, 3519-3522, 3531, 3582-3585, 3641 TZJ00108, 123-124

PARTS NEEDED

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No parts needed for this program

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 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 not 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 being performed. Follow the proper lock out tag out procedures to protect against unintended operation, 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 affected Masterpact NW circuit breaker serial numbers shown in Image 1 through Image 5 may not provide electrical protection capability. The circuit breaker serial number is located on the front of the circuit breaker. Refer to Image 6. The dealer is to contact the customer to determine if an affected breaker is in use. If an affected breaker is in use, the following actions are required.

1. Until the inspection is completed, special attention to ensure correct operation shall be provided by qualified personnel whenever circuit breaker operation occurs as a result of either manual or automatic operation, such as that is caused by, but not limited to, moving the circuit breaker handle from OFF (OPEN) to ON (CLOSED) and an internally or externally created trip command.

2. Provide the customer information sheet to Schneider Electric, arrange the date and time for dealer and Schneider Electric to conduct inspection at customer site, and provide assistance to Schneider Electric during inspection/replacement. Refer to the attached Rework Procedure.

Note: If a circuit breaker is found with a nonconforming internal circuit breaker component, Schneider Electric will provide a new replacement part. When the breaker requires replacement, the Dealer Technical Communicator shall notify the factory and submit a request to CPI number 425127 through CPI Feedback within the Service Information Management System (SIMSi).

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Image1

Image2

Image3

Image4

Image5

Image6

OWNER NOTIFICATION

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

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 2.0-hour job for Group 1
Note: It is mandatory to record the circuit breaker s/n in the warranty claim story for the claim to be paid.

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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 2.0-hour job for Group 2
Note: It is mandatory to record the circuit breaker s/n in the warranty claim story for the claim to be paid.

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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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE SCHNEIDER ELECTRIC AND SQUARE D BRANDED MASTERPACT NW CIRCUIT BREAKERS (800 AMPS TO 6300 AMPS), INSTALLED ON CERTAIN C27, C32, 3512, 3512B, 3512C, 3516, 3516B, 3516C, 3516E, C175-16, G3512, G3512H, G3516B, G3516C, AND G3516H GENERATOR SETS

MODELS INVOLVED - CERTAIN C27, C32, 3512, 3512B, 3512C, 3516, 3516B, 3516C, 3516E, C175-16, G3512, G3512H, G3516B, G3516C, AND G3516H GENERATOR SETS

Dear Cat Product Owner:

The Masterpact NW circuit breaker needs to be inspected and possibly replaced on the products listed below. The existing circuit breaker may have a nonconforming internal component. This may affect the electrical protection capability of the Masterpact NW circuit breaker. If the circuit breaker has the internal nonconformance, there is a risk that all poles on the circuit breaker may not open if the circuit breaker is called upon to interrupt current (trip), or if the circuit breaker is manually switched to the off position. If a pole/phase on a circuit breaker does not open as intended, this may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. Please contact your local Caterpillar dealer immediately to verify whether your circuit breaker is affected. You will not be charged for the service performed.

Until the inspection is completed, follow your facility?s normal procedures and industry standard electrical safety work practices to verify that all poles of the circuit breaker have opened properly.

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.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 31Jul2018 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 31Jul2018 Service Letter

Rework Procedure

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A. Schneider Electric Technician Scheduling

1. Call the customer and ask to confirm if their circuit breaker is listed on the affected circuit breaker serial number list.

2. Record the circuit breaker serial number. Proceed to the step 3 within 30 days even if you don?t receive a response from the customer.

3. Within the next 30 days, complete the customer information sheet and send it to Schneider Electric via fax # 859-817-5018 or an email to CharlotteServicesAdmin@schneider-electric.com. Refer to Image1.1.1.

4. Schneider Electric will coordinate with the dealer point of contact and the customer to arrange the date and time for the Schneider Electric technician?s circuit breaker inspection on the customer site and replacement if necessary.

B. Circuit Breaker Inspection At The Customer Site

1. Assist Schneider Electric to coordinate the customer visit. The Cat dealer technician shall accompany and assist the Schneider Electric technician at the customer site during the circuit breaker inspection.

2. The dealer technician shall remove the panels to gain access to the circuit breaker (If necessary).

3. After the circuit breaker inspection, ensure that the circuit breaker operates normally and that the generator is properly restored to operation.

4. If not previously collected, record the circuit breaker serial number and attach the customer information sheet to the service claim