PRODUCT SUPPORT PROGRAM FOR REWORKING THE ASR RELAY ON CERTAIN PM3516, XQ2000 POWER MODULES WITH AUTO PARALLELING CONTROLS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE ASR RELAY ON CERTAIN PM3516, XQ2000 POWER MODULES WITH AUTO PARALLELING CONTROLS

Usage:

REBE6237-00

02Aug2010


U-294

 
Before/After
  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE ASR RELAY ON CERTAIN PM3516, XQ2000 POWER MODULES WITH AUTO PARALLELING CONTROLS

4459 4460 7426
PS43132
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 "PS43132" 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.

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.


TERMINATION DATE

31Aug2013

PROBLEM

The existing ASR relay is used to open the generator breaker when operating in AUTO mode and the unit is signaled to stop. Occasionally the ASR relay will fail to drop-out. When this happens it will affect the operation in one of two possible ways:

1. If operating in either single unit-stand alone mode or in island mode paralleling, then the engine will go into cooldown/stop but the generator breaker will remain closed until the engine reaches zero RPM.

2. If operating in utility mode paralleling, then the engine will go into pre-cooldown(continuing to baseload), will not ramp down, and the generator breaker will remain closed.

AFFECTED PRODUCT

Model Identification Number
PM3516 KEN00105, 110, 164, 167-174, 176-177, 179-180, 182, 184, 188-192, 194-197, 203-204, 206, 208-209, 211-212, 214-216, 219, 221, 223-232

NAM00107-00108, 112-114, 116-130, 133

PARTS NEEDED

Qty

Part Number Description
100 8T7875 WIRE
1 2250547 BLOCK-TERMINAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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

Steps need to be taken to correct the ASR relay drop-out issue.

1. Rework of certain wiring to the ASR relay.
2. Perform verification test.

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-5000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 2.0-hour job



PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
 


Rework Procedure


 
XQ2000 Auto Paralleling Control Box (Image1.1.1)
Image1.1.1
 
REWORK PROCEDURE

1. Install a new 225-0547 Terminal Block and label as "DI2". This requires making a space between existing terminals 'AP6' and 'AP7' then inserting the new terminal block in this space. Location of terminal strip is shown in Image1.2.1.
Image1.2.1
 
2. Wire #F406-AU206 (from EMCP 3 pin #55 to terminal 'AP7') must be moved from terminal 'AP7' to new terminal 'DI2'.

3. Wire #T981-RE162 going to relay 'ASR' shown in Image1.3.1 must be removed from 'ASR-24', re-routed, and brought to 'ASR-A2'.
Image1.3.1
 
4. Install new 100cm 16AWG black wire 8T-8730 from relay ASR-24 to new terminal 'DI2' and label as #F401,

Verification Testing
Refer to the Image 1.4.1 for the location of 1)"Auto Start" lamp and 2) "Local Start/Stop" switch required for verification testing.
Image1.4.1
 
VERIFICATION TESTING

NOTE: Testing requires only single unit to run and breaker to close to a dead bus. No load is required.

1. Verify EMCP 3 is in STOP mode (will remain in mode through step 8).

2. Unplug relay 'ASR' from its base (will remain unseated through step 12).

3. Activate remote start contact by jumpering customer terminals 'B-' and 'RR' (will remain in place through step 10).

NOTE: Customer terminals are located on the side of the power module next to the load cable bus bars access area.

4. Verify green "Auto start" lamp (ASL) is illuminated.

5. Inside the doghouse, remove jumper connecting terminals 'AP7' and 'AP8'. Refer to Image 1.2.1.

6. Verify the "Auto start" lamp goes OFF.

7. Install jumper to terminals 'AP7' and 'AP8' (this jumper must remain in place to enable remote start capability).

8. Verify green "Auto start" lamp is illuminated.

9. Press the AUTO button on the EMCP 3.

10. Verify engine does not crank.

11. Remove jumper (to terminals 'B-' and 'RR') and press STOP button on the EMCP 3.

12. Verify the "Auto start" lamp goes off.

13. Plug in relay 'ASR' to its base.

14. Install jumper to customer terminals '1UP-93' and '1UP-94' (lead unit select) to allow dead bus closing for testing purposes. Customer terminals are located on the side of the power module next to the load cable bus bars access area.

15. Press the AUTO button on the EMCP 3 (will remain in mode through end of test).

16. Switch the "Local Start/Stop" switch (LSS) to the ON position momentarily.

17. Verify green "Auto start" lamp is illuminated.

18. Verify engine cranks/runs and breaker automatically closes to a dead bus.

19. Switch the "Local Start/Stop" switch (LSS) to the OFF position momentarily.

20. Verify the breaker trips open immediately and engine enters cooldown/stop(you may then skip cooldown time if desired).

21. Verify the "Auto start" lamp goes OFF.

22. Activate remote start contact by jumpering customer terminals 'B-' and 'RR'.

23. Verify green "Auto start" lamp is illuminated.

24. Verify engine cranks/runs and breaker automatically closes to a dead bus.

25. Remove jumper (to terminals 'B-' and 'RR') and discard.

26. Verify the breaker trips open immediately and engine enters cooldown/stop (you may then skip cooldown time if desired).

27. Verify the "Auto start" lamp goes OFF.

Installation and testing is complete. Unit is ready to be put into service.
 
 

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