PRODUCT IMPROVEMENT PROGRAM FOR REWORKING SWITCHGEAR RELAYS ON CERTAIN PMC32 AND PM3516 POWER MODULES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING SWITCHGEAR RELAYS ON CERTAIN PMC32 AND PM3516 POWER MODULES

Usage:

REBE4621-00

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06Mar2009

U-94

A-83

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING SWITCHGEAR RELAYS ON CERTAIN PMC32 AND PM3516 POWER MODULES
4491 4493 4494		PI31643

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31643" 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 "PI31643" 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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NOTE:

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COMPLETION DATE	TERMINATION DATE
30Sep2009	31Mar2010

PROBLEM

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A control relay needs to be replaced on certain PMC32 and PM3516 power modules. The existing relay in a multiple unit paralleling scenario has the capability of closing a non-primary unit to an energized bus out of phase, which could result in significant equipment damage.

AFFECTED PRODUCT

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Model	Identification Number
PM3516	KEN00100-00162, 166, 171
PMC32	MED00100-00130, 132-163, 165-180

PARTS NEEDED

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Qty	Part Number	Description
1	3409380	KIT-TIMER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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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 1.0-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 REWORKING SWITCHGEAR RELAYS ON CERTAIN PMC32 AND PM3516 POWER MODULES

MODELS INVOLVED - PMC32 and PM3516 Power Modules

Dear Caterpillar Product Owner:

A control relay located within the switchgear needs to be replaced on the products listed below. The existing relay in a multiple unit paralleling scenario has the capability of closing a non-primary unit to an energized bus out of phase, which could result in significant equipment damage.

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 06Mar2009 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 06Mar2009 Service Letter

Rework Procedure

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1. Review procedure and ensure that all the required parts are on hand for Cat Parts Kit 340-9380.

Image1.1.1

2. Ensure the power source is removed prior to relay replacement.

3. Remove the relay clips ISO Part Number: SFA-202.

Image 1.2.1 shows the previous relay design.

Image1.2.1

4. Remove the relay designated as HBR 310.

5. Remove the existing wires from all terminal points on the relay base.

6. Remove the relay base.

7. Perform the wiring changes using the wire numbers included in images 1.3.1 and 1.3.2.

Image1.3.1

Image1.3.2

NOTE: Leave the wire labels intact when performing the following steps.
a. Remove the wire ferrules.
b. Strip 1/4 inch of insulation off the wire.
c. Install a split lug on the wire.

Image1.4.1

Image1.4.2

Image1.4.3

Image 1.4.3 shows the replacement relay design for wire location reference. Image shows relay base wired with ferrules prior to termination change. Use split lug termination, as desribed above, on all wires.

8. Install the new base for the HBR 310 (ISO Part Number: SY4S-05) in the same location as the base removed in step 6.

9. Land wires to the new relay base HBR 310 as listed in images 1.4.1 and 1.4.2. Match the callout numbers with the images for images 1.2.1 and 1.4.3 to identify proper terminal locations.

10. Verify settings on Timer Relay (ISO Part Number: GT5Y-2SN1A100).

Timer Relay Setting 1: X1
Timer Relay Setting 2: S
Timer Relay Setting 3: 3 (Rotate dial until red dial indicator is half way between 2 and 4)

11. Install timer on base, matching all 8 pin connections.
NOTE: Pins on timer can be damaged if installed improperly on base.

12. Install relay clips (ISO Part Number: SFA-202).

13. Restore power to the unit.