PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CONTROL ARRANGEMENT ON CERTAIN 3516C XQ2000 POWER MODULES WITH FLOORSTANDING CAT SWITCHGEAR Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CONTROL ARRANGEMENT ON CERTAIN 3516C XQ2000 POWER MODULES WITH FLOORSTANDING CAT SWITCHGEAR

Usage:

REBE6357-02

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19Nov2010

(Revised 16Feb2011)

U-466

A-383

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CONTROL ARRANGEMENT ON CERTAIN 3516C XQ2000 POWER MODULES WITH FLOORSTANDING CAT SWITCHGEAR
1408 4490		PI31821

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31821" 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 "PI31821" 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:	This Revised Service Letter replaces the 19Nov2010 (Revised 15Dec2010) Service Letter. Changes have been made to the polarity check description of the fan motor starter at A1 and A2 to match what is shown in Image 1.8.1 of Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31May2011	30Nov2011

PROBLEM

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On-board electronic modules such as the DIO module have failed due to abnormal DC power input. The existing wiring can lead to component failure resulting from exposure to electrical noise and battery voltage transients propagating through the control system.

AFFECTED PRODUCT

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Model	Identification Number
PM3516	KEN00100-00104, 106-109, 111-162, 166, 171, 185, 195, 202, 210, 213, 217-218 NAM00100-00106, 109, 115, 131-132, 134-143, 145-146, 148, 154, 202

PARTS NEEDED

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Qty	Part Number	Description
1	3E0105	MOUNT
1	8L8413	STRAP-CABLE
1	3586989	HARNESS AS
1	3586991	DIODE
1	3586993	CAPACITOR AS
1	3613775	COVER
1	3616920	HARNESS AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 28% 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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Areas of improvement need to be addressed in order to minimize electrical noise and battery voltage transients.

Devices found to be the source of the voltage transients are:

- Charging motor (generator masterpact breaker accessory)
- Close coil (generator masterpact breaker accessory)
- Shunt trip coil (generator masterpact breaker accessory)
- Radiator fan motor starter (coil)

1. Rework certain wiring to provide DC voltage transient protection on the unit.

2. Perform verification testing.

Refer to 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%

NOTE: This is a 8.0-hour job

PARTS DISPOSITION

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 THE CONTROL ARRANGEMENT

MODELS INVOLVED - 3516C XQ2000 POWER MODULES WITH FLOORSTANDING SWITCHGEAR

Dear Caterpillar Product Owner:

The control arrangement needs to be reworked on the products listed below. The existing wiring can lead to component failure due to exposure to voltage transients. 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 19Nov2010 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 19Nov2010 Service Letter

Rework Procedure

XQ2000, 3516C With Cat Switchgear Paralleling Controls (Image1.1.1)

Image1.1.1

NOTE: Check Jacket Water Fan Motor starter polarity according to Step 6 before removing 24VDC power.

IMPORTANT:

- Disconnect battery power from engine starter before beginning work.

Turn OFF the following:
- Engine Switch (located at the bottom of the doghouse).
- Paralleling Switch (located inside the CAT Switchgear).
- Switchgear DC Power (20A located inside the Cat Switchgear).

Remove the following fuses:
- FU516 -Fuse 10A/ FU403 -Fuse 10A / FU201 -Fuse 4A

1. Remove lower rear control panel cover and install terminal 'RC' on din rail above existing fuse assembly. Install cover below this terminal as shown in Image1.2.1.

Parts required:
358-6993 Capacitor Assembly ('RC')
361-3775 Cover

Image1.2.1

2. Install wiring harness with diode suppressor assembly inside control panel for generator breaker CLOSE and OPEN Coils. Wire terminations according to Image1.3.1 and Image1.3.2.

Parts required:
361-6920 Harness

Image1.3.1

Image1.3.2

3. Remove the front cover from the Masterpact breaker to begin installation of the diode assembly harness for the generator breaker charging motor(Image1.4.1).

Image1.4.1

4. Unplug the 2-pin connector shown in Image1.5.1.

Image1.5.1

5. Plug in the diode assembly harness between the two connectors and mount the diode assembly harness in the breaker cavity as indicated above. Secure the harness to the adhesive backed holder using a wire tie.

Parts required:
358-6989 Harness
3E-0105 Holder (adhesive backed)
8L-8413 Wire tie

Image1.6.1

6. Locate the JW Starter Box containing the fan motor starter(Image1.7.1).

Image1.7.1

IMPORTANT:

- Before installing the suppressor diode the polarity of wiring to the motor starter coil must be verified. The top wire connection must have a negative polarity. The bottom connection must have a positive polarity. Installing the suppressor with the wiring polarity swapped, may result in damage to components.

7. Install the diode for the radiator fan motor starter.
Mount the diode, as shown in Image1.8.1 at terminal A2 on the starter and terminate the wire at terminal A1 on the starter.

Parts required:
358-6991 Diode

NOTE: Center picture in Image1.8.1 has the bottom portion of the motor starter removed to show proper wire routing.

Image1.8.1

Verification Testing

1. Connect battery power to engine starter.

2. Install the fuses (FU516 Fuse 10A, FU403 Fuse 10A & FU201 Fuse 4A).

3. Turn ON engine switch.

4. Verify EMCP3, annunciator, and electronic trip unit (on generator Masterpact breaker) are powered up.

5. Turn ON Switchgear DC Power Breaker inside the Cat Switchgear.

6. Turn ON Paralleling Control Switch located inside the Cat Switchgear.

7. Verify the HMI and PLC are powered up.

8. Turn OFF Paralleling Control Switch located inside the Cat Switchgear.

9. Run the Generator in Manual Mode with local EMCP panel control.

10. Close the generator Masterpact breaker depressing the black button on the face of the breaker. Wait for 1 minute or until the radiator fan is running.

11. Open the generator Masterpact breaker using the red button on the face of the breaker.

12. Repeat Steps 10 and 11.

13. Turn OFF the generator. Manual test is complete. Proceed with auto mode test using Cat Switchgear.

14. Turn ON Paralleling Control Switch located inside the Cat Switchgear. Wait for HMI & PLC to power back up and then place the EMCP ECS in Auto position. Verify HMI Engine Control Switch (ECS) is in Auto position.

15. Start Generator with the "Start" push button on the HMI Panel.

16. Unit will start automatically and generator breaker should close automatically.

17. Verify that the radiator fan motor starter is energized after the time delay relay operates.

18. Locate the CBS and trip circuit breaker by holding at Trip position for 5 seconds. This will prevent the breaker from automatically closing again. Release CBS from Trip position, circuit breaker should automatically close. Remove RSS jumper. Generator breaker will immediately open and unit will go into cooldown mode.

19. Stop generator with "Stop" push button displayed on the HMI Panel. Generator breaker should immediately open and unit will go into cooldown mode.

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