PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE BREAKER CONNECTOR MOUNTING BOLTS AND INTERFACE WIRING CABLES ON CERTAIN 3516B AND 3516C PACKAGE GENERATOR SETS WITH 4000 AMP BREAKERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE BREAKER CONNECTOR MOUNTING BOLTS AND INTERFACE WIRING CABLES ON CERTAIN 3516B AND 3516C PACKAGE GENERATOR SETS WITH 4000 AMP BREAKERS

Usage:

REBE3109-00

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15Jan2008

U-30

A-27

D-23

O-26

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE BREAKER CONNECTOR MOUNTING BOLTS AND INTERFACE WIRING CABLES ON CERTAIN 3516B AND 3516C PACKAGE GENERATOR SETS WITH 4000 AMP BREAKERS
4461 1408 1420 4458		PI31434

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31434" 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 "PI31434" 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:

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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COMPLETION DATE	TERMINATION DATE
31Jul2008	31Jan2009

PROBLEM

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The breaker needs to be inspected on certain 3516B and 3516C generator sets equipped with the 4000 amp breaker. The existing 244-9911, 244-9912, 244-9913, 252-7378 and 252-7379 can fail if the connector mounting bolts are not properly tightened. Also, on some units cables were improperly landed on only one phase connector.

AFFECTED PRODUCT

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Model	Identification Number
3516B	PBR00152, 154-160, 195, 281, 285, 294, 390, 409, 423, 440, 442, 496-497 ZAP00304-00309, 351, 482, 501
3516C	SBJ00231, 286, 367-368, 434, 447, 449-450, 492 SBK00238, 240-243, 254-260, 263-267, 270-276, 289-290, 292, 299, 318-319, 321, 329-330

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE BREAKER CONNECTOR MOUNTING BOLTS AND INTERFACE WIRING CABLES ON CERTAIN 3500 PACKAGE GENERATOR SETS WITH 4000 AMP BREAKERS

MODELS INVOLVED - 3516 package generator sets

Dear Caterpillar Product Owner:

The 244-9911, 244-9912 and 244-9913 need to be inspected on the products listed below. The existing breaker can fail if it was incorrectly assembled. 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 15Jan2008 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 15Jan2008 Service Letter

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.

Item 2 - The referenced units may have been incorrectly assembled in the positioning of the breaker cables and the breaker connection bus bolt torques. See picture noted for the allen head bolts to check torque value which attach the connectors to the breaker. Proper bolt torque is between 142 - 159 lb-in. (16 - 18 Nm). Refer to Image 1.2.1

Image1.2.1

Item 3 - The referenced units may have been incorrectly assembled in the positioning of the breaker cables. Refer to Image 1.3.1 for the correct cable attachment. There should be an equal number per phase connector. There are two connectors per phase. Each connector is rated for 1/2 of the total phase current.

Image1.3.1

Item 4 - There are eight cables per phase from the generator bus bars. Four cables per connector is the proper orientation as indicated in Image 1.2.1. Please note that the same applies to any load cables attached to the output bus of the breaker. Any unit that has all eight phase cables attached to one connector has to be rewired as indicated in Image 1.2.1. Please contact your service representative if you have any questions concerning this program.

Item 5 - Clear generator area, reconnect batteries, and release emergency stop.

Item 6 - Run functional No Load test on Genset.