2004/08/01 Caterpillar

Engine:

3412C (S/N: DJN1-UP; 9EP1-UP; TFT1-UP; BCW1-UP)

3456 (S/N: CCB1-UP; CBX1-UP)

3516 (S/N: CMD1-UP)

3516B (S/N: FDN1-UP)

G3406 (S/N: KAR1-UP)

G3412 (S/N: KAP1-UP)

G3516 (S/N: CSZ1-UP)

G3516B (S/N: CME1-UP)

Description of Change: New Circuit Breakers are now being used on Griffin-packaged Engine Generator Sets. New P-Series and R-Series Circuit Breakers are replacing CK-Series and CM-Series Circuit Breakers on the above-listed serial numbers. R-Series Circuit Breakers entered production on 06July 2004. P-Series Circuit Breakers are expected to enter production during Fourth Quarter, 2004.

The R-Series Circuit Breaker represents a 2500 Amp (and 3200 Amp IEC) frame size. The P-Series Circuit Breaker (fourth quarter 2004) represents a 1200 Amp frame size.

Improvements to the R-Series and P-Series Circuit Breakers include:

• True RMS Sensing to reduce nuisance tripping caused by harmonic loads

• Pre-trip alarming

• Easier-to-install shunt trip units and auxiliary contacts (field interchangeable between R-Series and P-Series Circuit Breakers)

Upgrades and enhancements to the R-Series and P-Series Circuit Breakers include:

• Solid-state metering and protective relaying functions

• Integral ground fault detection

• Power monitoring

• Neutral protection

• Contact wear indication

• Power quality measurement

• Communications interfacing

Adaptable To: The new R-Series Circuit Breakers replace the former CM-Series Circuit Breakers that are shown in Table 1.

The R-Series Circuit Breakers have smaller mounting footprints. Due to this smaller footprint, R-Series Circuit Breakers require new circuit breaker mounting and cover panel groups (at assembly). Refer to Table 5.

Table 1

Replacing CM-Series Circuit Breakers with R-Series Circuit Breakers
	CM-Series	R-Series
Frame Rating	Former Group Part Number	Replacement Group Part Number (1)	Parts to Order	Quantity
1600	105-7933 Circuit Breaker As	252-7530 Circuit Breaker Gp	252-7458 Bus Assembly	1
			252-7526 Circuit Breaker As	1
		252-7534 Circuit Breaker and Mounting Group	9F-8759 Spacer	12
			252-7520 Plate	2
			1A-9579 Bolt	4
			5P-1075 Hard Washer	4
			5S-0003 Nut	4
			5S-7383 Bolt	2
			6V-8801 Nut	2
			8T-4121 Hard Washer	8
			8T-4133 Nut	4
			8T-4185 Bolt	4
			8T-4835 Bolt	12
			9L-9132 Washer	4

( 1 )

Part numbers in this column are not serviceable. Order the parts listed in the next column to the right.

Table 2

Replacing CM-Series Circuit Breakers with R-Series Circuit Breakers
	CM-Series	R-Series
Frame Rating	Former Group Part Number	Replacement Group Part Number (1)	Parts to Order	Quantity
2000	105-7927 Circuit Breaker Gp	252-7531 Circuit Breaker and Mounting Group	252-7458 Bus Assembly	1
			252-7527 Circuit Breaker As	1
		252-7537 Circuit Breaker and Mounting Group	9F-8759 Spacer	12
			252-7520 Plate	2
			1A-9579 Bolt	4
			5P-1075 Hard Washer	6
			5S-0003 Nut	4
			5S-7383 Bolt	3
			6V-8801 Nut	3
			8T-4121 Hard Washer	8
			8T-4133 Nut	4
			8T-4185 Bolt	4
			8T-4835 Bolt	12
			9L-9132 Washer	4

( 1 )

Part numbers in this column are not serviceable. Order the parts listed in the next column to the right.

Table 3

Replacing CM-Series Circuit Breakers with R-Series Circuit Breakers
	CM-Series	R-Series
Frame Rating	Former Group Part Number	Replacement Group Part Number (1)	Parts to Order	Quantity
2500	105-7934 Circuit Breaker As	252-7532 Circuit Breaker Gp	252-7458 Bus Assembly	1
			252-7528 Circuit Breaker As	1
		252-7538 Circuit Breaker and Mounting Group	9F-8759 Spacer	12
			252-7520 Plate	2
			1A-9579 Bolt	4
			5P-1075 Hard Washer	8
			5S-0003 Nut	4
			5S-7383 Bolt	4
			6V-8801 Nut	4
			8T-4121 Hard Washer	8
			8T-4133 Nut	4
			8T-4185 Bolt	4
			8T-4835 Bolt	12
			9L-9132 Washer	4

( 1 )

Part numbers in this column are not serviceable. Order the parts listed in the next column to the right.

Table 4

Replacing CM-Series Circuit Breakers with R-Series Circuit Breakers
	CM-Series	R-Series
Frame Rating	Former Group Part Number	Replacement Group Part Number (1)	Parts to Order	Quantity
3200 (IEC)	105-7935 Circuit Breaker As	252-7533 Circuit Breaker Gp	252-7457 Bus Assembly	1
			252-7529 Circuit Breaker As	1
		252-7539 Circuit Breaker and Mounting Group	5P-1075 Hard Washer	24
			5S-7383 Bolt	12
			6V-8801 Nut	12
			8T-4121 Hard Washer	44
			8T-4133 Nut	16
			8T-4185 Bolt	16
			8T-6466 Bolt	12
			9Y-4275 Film	1
			106-7697 Circuit Breaker Bar	2
			106-7716 Circuit Breaker Bar	3
			106-7718 Circuit Breaker Bar	1
			261-4926 Bus Bar	1
			261-4927 Bus Bar	2

( 1 )

Part numbers in this column are not serviceable. Order the parts listed in the next column to the right.

Table 5

Required Parts
Description	Former Part Number	Replacement Part Number
Mounting Gp - Bracket	122-0319	252-7525
Panel Assembly	122-0317	252-7535

Table 6

Accessories
Description	Former Part Number	Replacement Part Number
(Aux Contacts)	105-7932	244-9825
(Shunt Trip, 24VDC)	105-7938	244-9861

Table 7

Example: CM-Series to R-Series Field Retrofit Requirements
Part Description	Quantity	Refer to
Mounting Gp (P/N by breaker frame rating	1	Table 1 - Table 4
Mounting Gp - Bracket (252-7525)	1	Table 5
Panel Gp (252-7535)	1	Table 5
Accessories	As needed	Table 6

Additional circuit breaker part numbers (for example, those used in Custom product) are involved in this change and may require new mounting and panel group part numbers. Additions to this guide will be made accordingly.

A similar guide for replacing CK-Series Circuit Breakers (and accessories) with P-Series Circuit Breakers will be published Fourth Quarter 2004.

For the latest additions to this guide, consult your Caterpillar Dealer.