PRODUCT IMPROVEMENT PROGRAM FOR REPLACING GENERATOR TERMINAL RINGS ON CERTAIN HIGH VOLTAGE 3508, 3508B, 3512, 3512B, G3512, 3516, 3516B, G3516, G3516B GENERATOR SETS Caterpillar

PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

Refer to the safety information in SR4 HV and SR4B

HV Generator Operation and Maintenance Manual

(Media Number: SEBU7270) before starting this repair

Make sure the unit is off-line (disconnected from utility and/or other generators power service), and locked out. Only qualified electrical personnel should service the equipment.

1. Remove generator control cover to gain access to bus bars and power leads (cables).
2. Discharge bus bar and cable capacitance before touching any power lead.
3. Identify and label all power leads to assure they?re properly reinstalled upon completing the job.
4. Disconnect power leads from bus bar.

1. Make the bus-to-lug connection and the lead connections.
1. Trim the insulation on the lead wire.
1. Trim approximately 19 ? 25 mm (.75 ? 1 in) from the end of lead wire. Avoid cutting the stranding when removing the insulation. See Table 1 for the maximum allowable nicked or broken strands.
2. Make the clearance between the end of the insulation and the lug 6 mm(.25 in) (see Illustration 1).
1. Do not let the insulation embed in the copper stranding at the termination points.
2. The lugs require two axial crimps located on each painted band.
NOTE: Use Burndy crimp tool MY29-3 or MY29-11.

NOTE: With units between 5KV and 15KV, taper the insulation 19 ? 25 mm (.75 ? 1 in) (see Illustration 1).

NOTE: The pictures below illustrate typical procedure steps.



Step 1 Step 4



Step 2 Step 5



Step 3
 

Show/hide table

Number of copper wire strands	Maximum allowable cut or nicked strands
259  (7 strands/bundle x 37 bundles)	13


 

Table 1
 


 




Illustration 1




2. Insulate the lugs on 5 - 15 KV units as follows:
1. Cover with a 3 inch piece of shrinkable tubing (8T-2225)
2. Place the tubing 6 mm (.25 in) from the larger diameter barrel of the lug (see illustration 2). Apply heat to the tubing.

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

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

Attach. (1-Owner Notification)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING GENERATOR TERMINAL RINGS

MODELS INVOLVED - CERTAIN HIGH VOLTAGE 3508, 3508B, 3512, 3512B, G3512, 3516, 3516B, G3516, G3516B GENERATOR SETS

Dear Caterpillar Product Owner:

New generator terminal rings need to be installed on the products listed below. The terminal rings on high voltage generators can fail allowing the cable to short against the box housing. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated November 18, 2005 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to November 18, 2005 Service Letter