PRODUCT SUPPORT PROGRAM FOR REPLACING THE CPS BOX CONTAINED WITHIN THE CATERPILLAR 480V RATED AUTOMATIC TRANSFER SWITCH (ATS). Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CPS BOX CONTAINED WITHIN THE CATERPILLAR 480V RATED AUTOMATIC TRANSFER SWITCH (ATS).

Usage:

REBE2057-00

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11Jun2007

U-249

A-203

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CPS BOX CONTAINED WITHIN THE CATERPILLAR 480V RATED AUTOMATIC TRANSFER SWITCH (ATS).
4469		PS42428

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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 "PS42428" 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

30Jun2009

PROBLEM

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The CPS Box located inside the Caterpillar 480V rated ATS is experiencing a premature failure resulting from a flashover event occurring at the electrical trace termination points for the J7 Receptacle Plug located on the CPS printed circuit board.

AFFECTED PRODUCT

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Model	Identification Number
CBTS	TSC01538, 1540, 1542, 1549, 1551
CBTSCT	TSF01025, 1027
CBTSD	TSD01052-01054
CTG	TSA05753, 5781, 5791, 5806, 5808, 5811-5812, 5827, 5829, 5839, 5853, 5857-5859, 5863, 5865-5866, 5871, 5877, 5884, 5887, 5891, 5914-5915, 5917, 5921, 5923, 5950, 5952-5953, 5955, 5958-5961, 5977, 5983-5984, 5992-5993, 5997, 6008-6009, 6014-6015, 6022-6023, 6026, 6033, 6039, 6041, 6049, 6060, 6064, 6066-6068
CTGD	TSB01125, 1131-1132
CTS	TSG01747, 1751, 1753, 1756-1757, 1768, 1771, 1773, 1775, 1777, 1779-1780, 1782, 1784
CTSCT	TSE01093-01094
CTSD	TSH01085

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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The dealer must obtain pre-approval from the Caterpillar ATS Product Support Representative for any "after failure" extended labor charges or additional service repair parts as identified in the NOTES below.

The instructions provided within this document are to be implemented by a properly trained Caterpillar EPG service technician only.

Improper test equipment can fail and present a high voltage shock hazard to its user. Make sure that the testing equipment is designed for and correctly operated for the potential voltage or current value to be measured.

Prior to performing this service letter, the service technician should perform the following precautions:

- Ensure that the Genset Start Key is in the "OFF" position and temporarily remove the key to prevent inadvertent starting of the machine.
- Disconnect the Negative Battery Cable from the battery.

NOTES:
A. Upon receipt of this service letter, all servicing Caterpillar dealerships working this service program are to contact the following Caterpillar ATS Product Support representative in order to receive appropriate instructions regarding:
- Delivery coordination of the replacement CPS Box.
- Identify any additional repair parts that are required for an "after failure" incident.

Caterpillar ATS Product Support Representative
Chris Harper
Phone: (886) 883-3879 or (770) 442-9442 x124
FAX: (770) 664-6302
Email: helpdesk@isopowerlynx.com

B. If the repair being performed is an "after failure" event, determine any additional labor that may be required in order to properly clean the ATS, re-cabling requirements, and touch up painting of the enclosure. Inform the Caterpillar EPD Product Support Representative of your requirements and obtain pre-approval for the extended labor needed. Ensure that your Warranty Claim Story contains your pre-approval request and authorization.

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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%
0-9999 hrs, 0-999 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.5-hour job
The dealer must obtain pre-approval from the Caterpillar ATS Product Support Representative for any "after failure" extended labor charges or additional service repair parts as identified in the NOTES within the Action Required.

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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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SPECIAL TOOLS:
The servicing technician will require, at a minimum, the following tooling or devices when performing this service letter.

- Calibrated 600VAC rated Digital Multi-meter (DMM)

De-energizing the ATS

1. Locate the main Utility Service circuit breaker. Open the circuit breaker and tag-out the circuit breaker utilizing your approved safety standard procedures.

2. Locate the Genset Engine Control Switch (ECS) on the appropriate EMCP control panel. Place the ECS in the "OFF" position.

3. Locate the Genset Emergency Service circuit breaker. Open the circuit breaker
And tag-out the circuit breaker utilizing your approved safety standard procedures.

4. Locate the ATS. Utilizing your 600VAC rated DMM, confirm that the Utility
Service and Emergency Service input terminals are de-energized.

Replacement of the CPS Box

1. Locate the CPS Box inside the ATS. (Typically on the inside door panel).

2. Unplug the J5, J7 and JC connectors from the CPS Box. Refer to Image 1.1.1.

Image1.1.1

3. Remove the existing CPS Box from the ATS enclosure door.

4. Install the new CPS Box, 50P-1231RPL, where the original CPS Box was located.

5. Reconnect the J7, J5 and JC connectors to the new CPS Box. Ensure that you are connecting the correct wire harness plug to the appropriate CPS Box receptacle.

6. Ensure that the J7, J5 and JC connectors are properly secured and there are no loose terminal connections.

7. Close and secure the ATS enclosure door.

Energizing the ATS

1. Locate the main Utility Service circuit breaker. Remove the tag-out devices and Close the circuit breaker.

2. Locate the Genset Emergency Service circuit breaker. Remove the tag-out devices and Close the circuit breaker.

3. Locate the Genset Engine Control Switch (ECS) on the appropriate EMCP control panel. Place the ECS in the "AUTO" position.

4. Reconnect the battery negative cable on the battery.

5. Place the Genset Start Key in the "ON" position.

6. Utilizing your 600VAC rated DMM, confirm that the Utility Service input terminals and Customer Load terminals are energized.

7. Close and secure the ATS enclosure door.

8. Verify that the ATS Micro-Processor controller is operative and reads normal service voltage.

ATS System Test

1. Simulate a Utility Service interruption by ?Opening? the Main Utility Service circuit breaker.

2. Confirm that the Genset starts and is generating the appropriate voltage level.

3. Confirm that the ATS automatically transfers the Customer Load to the Genset.

4. Confirm that the ATS Micro-Processor controller is operative and is displaying the correct voltage level on all phases.

5. Simulate a restoration of Utility Service by "Closing" the Main Utility Service circuit breaker.

6. Confirm that the ATS automatically transfers back to the Utility Source.

7. Perform at least 2 test cycles by repeating steps 1 thru 6.

8. Confirm that the Genset automatically goes into Cool Down Mode and then turns OFF.

9. Service Program Completed.