PRODUCT SUPPORT PROGRAM FOR REPLACING HARNESS WIRE IN PM1000 POWER MODULES, ADDING FUEL CONTROL PANEL RELAY, AND ISOLATING CIRCUIT BREAKER SHUNT TRIP WIRING Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING HARNESS WIRE IN PM1000 POWER MODULES, ADDING FUEL CONTROL PANEL RELAY, AND ISOLATING CIRCUIT BREAKER SHUNT TRIP WIRING

Usage:

REBE2773-00

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02Jan2008

U-2

D-1

O-1

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING HARNESS WIRE IN PM1000 POWER MODULES, ADDING FUEL CONTROL PANEL RELAY, AND ISOLATING CIRCUIT BREAKER SHUNT TRIP WIRING
1408 1422 4493		PS42592

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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 "PS42592" 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

31Jan2010

PROBLEM

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The existing wiring can cause issues during generator set shutdown on certain PM1000 power modules. If the existing wire is not changed, it can/will continue to cause engine failure 190-2 (Engine Speed Sensor-Erratic/Lost) to be erroneously reported.

This situation will only arise when the set is not running or during the shutdown process, and could force the operator to reset the unit completely before it can be restarted. In addition to this, the circuit breaker's shunt trip wiring requires isolation due to the installation of new terminal blocks on the AC/DC Box and the corresponding software to make these blocks operational.

A Fuel Control Panel Relay also needs to be added for product improvement purposes.

AFFECTED PRODUCT

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Model	Identification Number
PMC32	MED00100-00125

PARTS NEEDED

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Qty	Part Number	Description
10	1304672	WIRE-BULK
110	1346258	CABLE-ELECTRICAL
1	1798846	RELAY
1	1798847	BASE-RELAY
In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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Refer to the attached Rework Procedure.

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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 4.0-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.

Rework Procedure

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Refer to appropriate service manual as necessary.

Item 1 - Isolate Genset before commencing any work on the unit, open Genset breaker, activate Emergency Stop, and disconnect battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

REFER to Image 1.1.1 for Items 2 through 4.

Item 2 ? Remove R04 from circuit breaker operation - Clip and stow wire labeled E565-MR1 from harness 297-4772 (landed on RO4-NO terminal in AC/DC Box). Clip and stow wire labeled E565-MK1 from harness 297-4771(landed on MX-C2 terminal on Ckt Bkr)? There is a possibility that this wire may also read (T1/E565/T14) depending on the harness rev.

Item 3 ? Isolate circuit breaker shunt trip wiring - remove from BATT- wires 229-MB2. Re-land on new terminal block (192-2922) labeled CBBN. Add 100 mm of jumper cable (1304672) on Ckt Bkr from MX-C1 to XF-A1.

Item 4 ? Isolate circuit breaker shunt trip wiring - Remove interconnect wire from BATT+ labeled BP-TB47. Re-land on new terminal block(192-2922) labeled CBBP.

Item 5 ? Isolate circuit breaker shunt trip wiring - Add two wires from Battery Positive and the Keyswitch (Neg) (12awg wires) to two new terminals in AC/DC box ? labeled CBBP & CBBN (from items 2 & 3).

Image1.1.1

Item 6 ? Isolate circuit breaker shunt trip wiring - Update PLC program with C3G0402.PRZ. Program can be downloaded from ISO Website http://www.catswitchgear.com/login.asp).

Username: "catpm", password "caterpillar". Click on "Power Module", open folder "297-6974", then click on "PLC" to find file.

Item 7 ? Proper Termination of Mag Pickup Shield. Locate the wire labeled "838 AC19" on the customer wiring box of the EMCP (see Figures 1.2.1 and 1.2.2). Disconnect this wire from the box and connect directly to BAT-.

Image1.2.1

Image1.2.2

Item 8- Fuel control panel relay addition - Add a Relay to the terminal strip in the lower section of the fuel control panel. Part Numbers 179-8847 (base) and 179-8846 (relay) should be used. Remove wire labeled [H2] from terminal 609. Re-land on a new terminal labeled 650. Add a wire labeled [609] from the Relay Coil [pin 1] to terminal 609. Add a wire labeled [2] from the Relay Coil [pin 5] to terminal 2. Add a wire labeled [609] from terminal 609 to the normally open relay contact [pin3]. Add a wire labeled [2] from the normally open relay contact [pin4] to terminal 2.

Image1.3.1

Item 9 - Paralleling Panel HMI CF card (supplied by Brent Center)- Confirm that the
touchscreen HMI has a compact flash card with firmware PM1001. Make sure Dip Switch One in CF card bay is pushed down, and that Dip Switches 3 thru 4 are pushed up.

Item 10 - Verify Circuit Breaker Wiring- Using the latest Schematics, verify that the wiring matches. Specifically:
1. X712-MR12 is landed on [CLOSE].
2. X713-MR10 is landed on [OPEN].
3. 229-MR11 has been moved to a new terminal [OTS-COM] and relabeled A782-MR14.
4. E565-MR1 has been moved to a new terminal [OTS-NO] and relabeled A770-MR13.
5. 229-MR3 has been moved to a new terminal [AUX-COM].
6. F407-MR8 has been moved to a new terminal [AUX-NO].
7. X712-MK12 is landed on [XF-A2].
8. X713-MK10 is landed on [MX-A2].
9. 229-MK11 is landed on [SDE-81] and relabeled A782-MK14.
10. E565-MK1 is landed on [SDE-84] and relabeled A770-MK13.