PRODUCT SUPPORT PROGRAM FOR REPLACING THE DEIF CONTROLLER ON CERTAIN PMG3516C (XQ1475G) POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE DEIF CONTROLLER ON CERTAIN PMG3516C (XQ1475G) POWER MODULES

Usage:

TEBE2835-00

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30Mar2015

U-136

A-93

D-114

O-113

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE DEIF CONTROLLER ON CERTAIN PMG3516C (XQ1475G) POWER MODULES
7610 7620		PS52901

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
NOTE:	This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52901" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31Mar2019

PROBLEM

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The existing controller can fail on certain PMG3516C (XQ1475G) Power Modules. If the controller fails it will need to be replaced.

AFFECTED PRODUCT

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Model	Identification Number
PMG3516C	JKK00107, 119, 123, 127, 130, 132, 134, 136-137, 140-144, 148-149, 157, 161-162, 172, 180, 184, 186-188, 190-193, 195-196, 198-232, 234-235

PARTS NEEDED

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Qty	Part Number	Description
1	3928122	CONTROLLER
1	SOFTWARE	ULTILITY SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident
occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

REWORK ACTION REQUIRED

Certain 3928122 DEIF Controllers will need to be removed and replaced. The replacement controller will need to be configured with a batch file with a .usw extension using DEIF Utility Software. The Utility Software can be downloaded directly from DEIF
1. Go to www.deif.com
2. Select Documentation & Software
3. Select Software download
Service Letter -- Preview Page 3 of 11
https://pubtool.cat.com/pubtool/SlCreateAction.do-printpreview=yes 3/12/2015
4. In the dropdown menu, select Multi-line 2 utility software v.3.x
5. Fill in your e-mail address and click "Submit"
You will now receive an e-mail containing a link. Click the link and
follow the instructions.
The software is now installed on your computer.
Installation of USB drivers
On Windows Vista machines the USB drivers are installed automatically.
For Windows XP machines follow the procedure below.
When you connect the controller, Windows XP will launch two "Hardware
Wizards". Two drivers are installed, let Windows execute both "Found
new Hardware Wizard".
Let the Hardware Wizard install the software automatically by choosing
the "Recommended" option. If the "Advanced" option is chosen, the
needed files are available from the USW3 installation folder (default:
C:Program FilesDEIFUSW3) in the "USB driver files/source
PreInstaller" folder. Please select "Continue Anyway" if a "Hardware
Installation" warning appears during
the installation. Image 1
The .usw batch file can either be downloaded from the faulty controller
by clicking the "Write/Read icon" (Image 1.12.1 in the rework procedure)
and selecting "Read from device" If that is not possible then save the
file from another similar unit. If both methods are not successful
request a copy of the file by contacting product service engineer Jo
Liang at Liang_Jo@cat.com.
Refer to the attached Rework Procedure.

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Image1

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%
0-10000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
10001-15000 hrs, 37-48 mo	50.0%	50.0%	50.0%	50.0%	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.

Rework Procedure

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WARNING: Verify that the Power Module is keyed off at the battery disconnect switch. Verify a dead bus on the load side of the open breaker. Isolate the bus measurement terminals by removing the .5 amp fuses 10,11,12. Image1.1.2

Locate the switchgear cabinet in the personnel access area of the Power Module. Open the access door and locate the controller. Verify that power has been removed from the controller as indicated by the LED status lights.

Image1.1.1

Image1.1.2

Record the serial number of the original and the replacement controller in a SIMs entry against the serial number of the power module.

Image1.2.1

Remove all green terminal blocks by pulling each away from the controller housing. Leave wires attached to the blocks while doing so. Remove both ethernet and display cables. Image1.3.1

Image1.3.1

Remove the 6 M4 mounting screws while supporting the controller. Release and remove the controller. Discard the controller.

Image1.4.1

Image1.4.2

Mount the new controller and install the 6 M4 screws removed in the previous step. Tighten the screws to 1.5 Nm. Take care not to overtighten. Reconnect all green terminal blocks and cables. Check that all wires to the terminal blocks are fully inserted and secure and that all screws are tightened to .5 Nm. Turn the key switch to power on the controller. Connect a standard USB cable to the service port on the controller and to the usb port on the computer.

NOTE: To aid in reinstallation match the terminal blocks to the white terminal numbers printed on the controller housing. Image1.5.1

Image1.5.1

On the computer click on the Utility Software icon

Image1.6.1

The window below appears. Click on the "Application settings" icon.

Image1.7.1

Open "Windows device manager"

Image1.8.1

Check the COM port used for communication, and make sure the settings correspond to
the application settings.

Image1.9.1

Click the "Connect" icon

Image1.10.1

The password window will appear. Select "master" for "New level" and enter "2002" for the password. Click "OK"
You are now online with the controller

Image1.11.1

Click on the "Write/Read" icon as shown in Image1.12.1 Select "Write to device".

Image1.12.1

A window will appear prompting "Do you want to open a project file now-". Click on "Yes". The file selection window will appear. Locate the .usw batch file and click "Open". The configuration will load.

Image1.13.1

Disconnect the USB cable from the service port and close the cabinet door. Install fuses 10,11,12. Put the controller in "LOCAL" mode and press the START button to verify genset operation.
Once you are satisfied that the controller is operating correctly, stop the genset and put the controller in "REMOTE" mode to return the Power Module to service.