PRODUCT SUPPORT PROGRAM FOR REWORKING THE COMMUNICATION NETWORK ON CERTAIN PMG3516C (XQ1475G) POWER MODULES Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE COMMUNICATION NETWORK ON CERTAIN PMG3516C (XQ1475G) POWER MODULES

Usage:

TEBE3161-00

03Jun2015


U-283
A-195
D-227
O-233

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE COMMUNICATION NETWORK ON CERTAIN PMG3516C (XQ1475G) POWER MODULES

7610 7620 1408
PS52954
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 "PS52954" 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.

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

30Jun2017

PROBLEM

Overburden of the existing communications network can cause the ECM to reset leading to a shutdown of the power module. Shutdown of other paralleled Power Modules can occur if the remaining load supported exceeds the available power.

AFFECTED PRODUCT

Model Identification Number
PMG3516C  JKK00100-00118, 120-133, 135-139, 141-171, 173-186, 188, 192-194, 196-197, 199-205, 208-211, 213-214, 216-218, 220, 224, 226, 228, 231, 234-236, 241-244, 246, 253, 255, 257-260, 265-275, 277, 282-283, 314, 317-325

PARTS NEEDED

Qty

Part Number Description
1 1342540 RECEPTACLE RESISTOR
1 1743016 PLUG RESISTOR
1 SOFTWARE1 PL1000 CONFIGURATION (see Action Required)
1 SOFTWARE2 ADVISOR PANEL (see Action Required)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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

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

The communication network on certain PMG3516C (XQ1475G) Power Modules will require rework. This includes modifications to CAN as well as Cat Data Link CDL.

The changes to the communication network are detailed in the rework procedure in the following sections.

- Dividing CAN into two separate networks
- Permanently removing the DEIF controller from CAN
- Removing protectives assigned to engine parameters on the EMCP
- Reprogramming the PL1000
- Installing new Advisor Panel software
- Installing a ground wire to the negative terminal on the speed signal converter

Please send an e-mail request to Product Service Engineer Jo Liang at Liang_Jo@cat.com for all software files required for the procedure.

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%
0-15000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job

If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.




PARTS DISPOSITION

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


Rework Procedure


 
DIVIDING THE CAN NETWORK INTO TWO SEPARATE NETWORKS
1) Isolate the engine CAN network

Parts Required
1 174-3016 Plug Resistor
1 134-2540 Receptacle Resistor

Disconnect harness 390-8816 from the ECM box located on the engine Image1.1.1. Install a 174-3016 plug resistor in the receptacle that the harness was removed from. Image1.1.2
Image1.1.1
Image1.1.2
 
Add a 134-2540 120 ohm receptacle resistor to the plug connector on the harness. Image1.2.1
Image1.2.1
 
PERMANENTLY REMOVING THE DEIF CONTROLLER FROM THE CAN NETWORK

Open the controller cabinet in the personal access area.
Remove the green terminal block and the 120 ohm resistor from terminals 29 CAN(H) and 31 CAN(L) shown in Image1.3.1 on the controller. Only remove the resistor. Check to see if wires 2020 and 2040 have loosened during the process. Secure wires and tighten terminals if required. Plug the terminal block back into the controller.

Remove the 3 CAN wires (2020 Yellow CAN(H), 2040 Green CAN(L), and Shield CAN(G)) from terminals TB1-1, TB1-2, and TB1-3 at the location shown in Image 1.3.2. Store the loose wires in the Panduit.
Image1.3.1
Image1.3.2
 
Use either the 120 ohm resistor removed from the previous step or an additional spare located behind the cabinet door. Install it on terminal TB1-1 and TB1-2 at the location where the CAN (H,L)network wires were removed from the previous step. Image1.4.1
Disable CAN communication failure shutdown in the DEIF controller by going to menu 7561 and selecting "Disable" for CAN interface.
Image1.4.1
 
EMCP4.2 SETTING CHANGES
Once CAN is split between the engine and generator control components all the engine parameters originally communicated via CAN will not be displayed. All values for those parameters will be replaced by "*****" and will trigger all associated shutdowns and warnings programmed. These events need to be disabled through ET in section Event Response Configuration for the EMCP Image1.5.1. Disable low oil pressure and high coolant temperature events on the EMCP. These events are redundant and remain active on the engine ECM displayed by the Engine Monitoring System (Advisor Panel).
Image1.5.1
 
PL1000 SETTING CHANGES

Parts Required
1 SOFTWARE1

Install the new settings file with a lower update rate by following these steps with a computer. The computer must be configured in order to connect to the PL1000 over Ethernet. Please refer to REHS4498 in SISweb for instructions.
Setup FTP on the computer by right clicking the Computer icon and selecting "Add a Network Location" Image 1.6.1. Click "Next" for the next two windows that appear. Image1.6.2, 1.6.3.
Image1.6.1
Image1.6.2
Image1.6.3
 
Type in as shown the IP address that has been set for the PL1000 in the "Address" bar. A demo IP address is shown in Image1.7.1 with the format FTP://admin@xxx.xxx.xxx.xxx
Image1.7.1
 
Click "Next". In the next window create and type in a name for the network location. In the example (Image1.8.1) "PL1000E" was entered as the name.
Image1.8.1
 
Once you finished setup you will see the FTP network as indicated by the cursor in Image1.9.1.
Image1.9.1
 
Click on the network, once connected log in with the default username "admin" and password "admin". 4 folders will appear. Select and drag the new XQ1475G_PL1000E_NOV2014.pcl file into the "New" folder.
Image1.10.1
 
Cycle the power to the PL1000. After the power has been applied click "View" then click "Refresh" The .pcl file should disappear. The file will move from the "New" to the "Current" folder. Verify that the file is now located in the "Current" folder. The process is complete. For more information refer to the PL1000 Quick Reference Guide REHS4498.
Image1.11.1
 
INSTALL NEW ADVISOR PANEL SOFTWARE

Parts Required
1 SOFTWARE2

Update the Engine Monitoring System panel with the new 3521125-05.fls. flashfile.
Image1.12.1
 
INSTALL GROUND WIRE ON THE SPEED SIGNAL CONVERTER
Ground the analog to PWM speed converter inside the control cabinet by installing a wire from the output negative (-) to chassis ground.
Image1.13.1
Image1.13.2
 
The power module can now be returned to service.
 
 

Caterpillar Information System:

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