PRODUCT SUPPORT PROGRAM TO REWORK THE BREAKER OVERLOAD TRIP MODULE ON CERTAIN 3406C, 3412C, C15, AND C18 GENERATOR SETS TO OPERATE ON THERMAL AND SHORT CIRCUIT EVENTS Caterpillar

PRODUCT SUPPORT PROGRAM TO REWORK THE BREAKER OVERLOAD TRIP MODULE ON CERTAIN 3406C, 3412C, C15, AND C18 GENERATOR SETS TO OPERATE ON THERMAL AND SHORT CIRCUIT EVENTS

Usage:

REBE6483-00

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14Mar2011

U-101

A-84

D-90

O-94

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*Before/After*	PRODUCT SUPPORT PROGRAM TO REWORK THE BREAKER OVERLOAD TRIP MODULE ON CERTAIN 3406C, 3412C, C15, AND C18 GENERATOR SETS TO OPERATE ON THERMAL AND SHORT CIRCUIT EVENTS
1420 4461		PS43244

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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 "PS43244" 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

31Mar2013

PROBLEM

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The existing T7 1250A Trip Module will only function with a short circuit on certain 3406C, 3412C, C15, and C18 Generator Sets. The trip unit needs to be changed so that it will operate on thermal as well as overload events.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3406C	C2G06178-06180, 6182, 6187-6188, 6190, 6192-6196, 6199-6200, 6202-6203, 6205, 6209-6212, 6215, 6222, 6224, 6230-6231, 6336, 6340-6344, 6346, 6348, 6352, 6354, 6358-6362, 6367-6369, 6372-6373, 6395, 6417
C15	C5L03533, 3535, 3540, 3552-3553, 3555-3556, 3559, 3591, 3593-3596, 3606, 3648-3649, 3651, 3662, 3701, 3712-3715, 3730 NKL00122-00131, 142-145, 147-149, 151-153
C18	DKE00526-00527 G4C04692, 4694-4696, 4706, 4712-4714, 4717, 4725, 4729-4730, 4732-4733, 4735-4736, 4739, 4747, 4760-4761, 4766-4767, 4770, 4773, 4782-4786, 4809-4812, 4826-4829, 4835, 4838-4839, 4841-4847, 4849, 4852-4853, 4857-4858, 4863-4864 M1Y00100-00101 M1Z00509, 514, 517, 523, 525-527, 529, 532-533, 536-552, 554-559, 561-566, 568-571, 573-577, 579-583, 585-586, 589, 591, 595-602

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*****Group 2*****
3412C	RTY00624-00628, 633, 650, 652-653, 656, 663, 665-667, 671-673, 675, 677, 679, 681-682, 684-685, 687, 690-692, 694, 697-698, 701, 704, 707-708, 712, 714-715, 718-720, 724-725, 730, 732, 734, 742, 744, 748

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*****Group 3*****
3412C	RTY00632, 636, 639-640

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*****Group 4*****
3412C	RTY00630, 634, 637

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*****Group 5*****
C18	DKE00528-00530 G4C04851 M1Z00510, 513, 518, 528, 535, 578, 588

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3665609	BREAKER - TRIP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*****Group 2*****
1	3665609	BREAKER - TRIP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*****Group 3*****
1	3665610	BREAKER - TRIP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*****Group 4*****
1	3665609	BREAKER - TRIP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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.
*****Group 5*****
1	3665610	BREAKER - TRIP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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%
*****Group 1*****
0-100 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
101-2000 hrs, 13-24 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 0.5-hour job for Group 1

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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%
*****Group 2*****
0-100 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
101-500 hrs, 13-24 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 0.5-hour job for Group 2

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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%
*****Group 3*****
0-100 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
101-500 hrs, 13-24 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 0.5-hour job for Group 3

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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%
*****Group 4*****
0-100 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 0.5-hour job for Group 4

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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%
*****Group 5*****
0-100 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
101-1000 hrs, 13-24 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

NOTE: This is a 0.5-hour job for Group 5

PARTS DISPOSITION

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

Rework Procedure

Refer to the Service Manual as necessary.

1. Ensure that the generator set has been safely isolated from starting, and that the generator set breaker is in the tripped position.

2. Remove the front panel of the breaker box.

3. Remove the front of the switch cover from the breaker as shown in Image 1.1.1

Image1.1.1

4. After the front switch cover has been removed undo the four screws as shown in Image 1.2.1.

Image1.2.1

4. Remove the two screws as shown in Image 1.3.1 and the small electrical plug. Please pay attention to the orientation of the plug and also the wire loop as shown in Image 1.3.2.

Image1.3.1

Image1.3.2

5. Remove the old trip unit off the breaker and remove the small rating plate from the front of the breaker as shown below in image 1.4.1.

Image1.4.1

6. Fit the new trip unit making sure to attach the small wire loop of the electrical plug and then secure with the two screws as shown below in Image 1.5.1. The small rating plate from Image 1.4.1 can also be fitted at this time.

Image1.5.1

7. Refit the breaker front cover and secure with the four screws as shown in Image 1.6.1.

Image1.6.1

8. Refit the front switch cover as shown in figure 1.7.1.

Image1.7.1

9. Check the breaker opens and closes and trips manually. Then set the dip switches for the trip and overload settings. Refit the breaker box front cover to protect from electric shock.

10. Re-connect the generator set batteries and test the generator operates normally and that the breaker operates correctly.