PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE BUS MOUNTING HARDWARE USED WITH MASTERPACT CIRCUIT BREAKERS (800 TO 6,300 AMP) ON CERTAIN C32, 3512, 3512B, 3516, 3516B, 3516C, AND C175-16 GENERATOR SETS, PM3516, AND PMG3516C Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE BUS MOUNTING HARDWARE USED WITH MASTERPACT CIRCUIT BREAKERS (800 TO 6,300 AMP) ON CERTAIN C32, 3512, 3512B, 3516, 3516B, 3516C, AND C175-16 GENERATOR SETS, PM3516, AND PMG3516C

Usage:

REBE9279-00

26Feb2013


U-79
A-62
D-72
O-77

 

Safety

  
  

PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE BUS MOUNTING HARDWARE USED WITH MASTERPACT CIRCUIT BREAKERS (800 TO 6,300 AMP) ON CERTAIN C32, 3512, 3512B, 3516, 3516B, 3516C, AND C175-16 GENERATOR SETS, PM3516, AND PMG3516C POWER MODULES

4461 1420 445B
PI10922
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10922" 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 "PI10922" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.



PROBLEM

A potential nonconformance with the bus mounting hardware used with Masterpact NW circuit breakers (800 to 6,300 Amp) has been identified on certain C32, 3512, 3512B, 3516, 3516B, 3516C, and C175-16 Generator Sets, PM3516, and PMG3516C Power Modules. These circuit breakers may have a nonconforming washer on primary terminals mounting screws. If the washer is not conforming, there is a risk of low clamp force between the terminal and the breaker/cradle. This can result in overheating at the loose connection. Should this occur there is a potential for property damage, or that the circuit breaker may not operate as intended.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C32  JSJ02521-02522, 2528, 2531, 2549, 2551, 2571, 2669
*******Group  2*******
3512  YAK00640-00644
3512B YAM00679, 707, 713, 717, 722-723, 725-726

YAN00264-00268
3516B YAT00794-00795, 809-810, 815, 820, 822, 825-826, 829, 831, 843, 847, 850, 857, 861, 873

YAW00414-00415
3516C SBJ00855, 1412, 1416-1417, 1423, 1426

SBK01381
*******Group  3*******
3516  YAS00530, 532
3516C  SBK01371-01375, 1379-1380, 1384, 1386-1387, 1389, 1400, 1407, 1412-1413
C175-16  WYB01049, 1054, 1056, 1066-1067, 1072, 1079, 1082-1084
*******Group  4*******
PM3516  NBR00452, 460-469, 523-524, 530, 545-547, 561-564
PMG3516C  JKK00163, 170, 177, 179, 181-182
*******Group  5*******
PM3516  NBR00436, 438, 446, 496-502

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 4223734 KIT-BREAKER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 4223734 KIT-BREAKER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 4223735 KIT-BREAKER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 4223734 KIT-BREAKER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 4223735 KIT-BREAKER
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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

Inspection:

1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all 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 operation and disconnect/lockout all power sources before commencing any work.

2. Locate the circuit breaker on the genset package.

3. Record the breaker s/n and date code. The breaker s/n and date code are located on the front of the circuit breaker or on the right side of the cradle. (see Image 1 and Image 2)

4. If the breaker serial number is not listed in the affected breaker s/n list (see Image 3), do not perform the rework. Record the breaker serial number and date code in the claim story as per the example below:

"Breaker s/n: 0851xxxx, date code: xxxx was not listed in the affected breaker s/n list. This claim is for inspection only."

5. If the breaker serial number is in the affected breaker s/n list (image 3), proceed with the rework procedure and document the claim story as per the example below:

"Breaker s/n: 0851xxxx, date code: xxxx was reworked as per SLxxxx a total of xx bolts were replaced and found xx washers with cracks."

Note: It is mandatory to record the breaker s/n and date code in the warranty claim story for the claim to be paid.
Image1
Image2
Image3

OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.0-hour job for Group 1
Note: This is a 1 hour job for inspection only and an additional 2 hours is allowed for the repair.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.0-hour job for Group 2
Note: This is a 1 hour job for inspection only and an additional 2 hours is allowed for the repair.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.0-hour job for Group 3
Note: This is a 1 hour job for inspection only and an additional 3 hours is allowed for the repair.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.0-hour job for Group 4
Note: This is a 1 hour job for inspection only and an additional 4 hours is allowed for the repair.

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 1.0-hour job for Group 5
Note: This is a 1 hour job for inspection only and an additional 4 hours is allowed for the repair.


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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE BUS MOUNTING HARDWARE USED WITH MASTERPACT CIRCUIT BREAKERS (800 TO 6,300 AMP) ON CERTAIN C32, 3512, 3512B, 3516, 3516B, 3516C, AND C175-16 GENERATOR SETS, PM3516, AND PMG3516C POWER MODULES

MODELS INVOLVED - C32, 3512, 3512B, 3516, 3516B, 3516C, C175-16, PM3516, PMG3516C

Dear Caterpillar Product Owner:

A potential nonconformance with the bus mounting hardware used with Masterpact NW circuit breakers (800 to 6,300 Amp) has been identified on certain C32, 3512, 3512B, 3516, 3516B, 3516C, and C175-16 Generator Sets, PM3516, and PMG3516C Power Modules. These circuit breakers may have a nonconforming washer on primary terminals mounting screws. If the washer is not conforming, there is a risk of low clamp force between the terminal and the breaker/cradle. This can result in overheating at the loose connection. Should this occur there is a potential for property damage, or that the circuit breaker may not operate as intended. 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 26Feb2013 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.



Caterpillar Inc.

Identification #(s)



Attached to 26Feb2013 Service Letter


Rework Procedure


 
1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. Ensure all 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 operation and disconnect/lockout all power sources before commencing any work.

2. Remove the generator covers to get access to the rear of the breaker. (see Image 1.1.1).
Image1.1.1
 
A. BREAKERS WITH ONE LEVEL OF COPPER:

3. Mark old M8 screw with red marker (or any other color to identify bolts that have not been replaced). See Image 1.2.1.
Image1.2.1
 
4. Remove and replace each M8 bolt individually until all M8 bolts have been replaced with new as per the instructions below:

Install new hardware by hand starting each M8 screw and washer assembly and tighten to 16 Nm. Mark each new M8 screw and washer assembly with a green permanent marker or with a different color marker than used previously (this is to confirm all bolts have been changed and tightened to the proper torque). See Image 1.3.1.
Image1.3.1
 
5. IMPORTANT: Record the breaker s/n, date code, total number of bolts replaced and number of washers with cracks if any. This information is going to be needed to submit the claim (refer to the Action Required).

B. BREAKERS WITH TWO LEVELS OF COPPER:

6. Breakers with 2 levels of copper will require removing the top level first. Mark old M8 screw and washer assemblies with red permanent marker (or any other color to identify bolts that have not been replaced). Remove old M8 screw and washer assemblies. Set top level copper aside. See Image 1.4.1.


7. Mark old M8 screw and washer assemblies on lower level with red marker (or any other color to identify bolts that have not been replaced). Remove old M8 screw and washer assemblies. See Image 1.4.2.
Image1.4.1
Image1.4.2
 
8. Install new M8 screw and washer assemblies on lower level by hand starting and tighten to 16 Nm. Mark new M8 screw and washer assemblies with green permanent marker or with a different color marker than used previously (this is to confirm all bolts have been changed and tightened to the proper torque). See Image 1.5.1.
Image1.5.1
 
9. Install new M8 screw and washer assemblies on top level by hand starting, tighten to 16 Nm and mark with permanent marker using any color other than red or used previously (this is to confirm all bolts have been changed and tightened to the proper torque). See Image 1.6.1.
Image1.6.1
 
10. IMPORTANT: Record the breaker s/n, date code, total number of bolts replaced and number of washer with cracks if any. This information is going to be needed to submit the claim (refer to the Action Required section).


11. Perform the following to restore the generator to the proper operational condition:

a. Reconnect battery cables and close the control circuit breaker for the AC power supply to the battery charger.

b. Energize the battery charger.

c. Deactivate the emergency stop.

d. Restore the generator set to the proper operational condition and reconnect the power supply.
 
 

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