PRODUCT SUPPORT PROGRAM FOR REPAIRING THE CONTROL PANEL ON CERTAIN CTG, AND CTS AUTOMATIC TRANSFER SWITCHES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING THE CONTROL PANEL ON CERTAIN CTG, AND CTS AUTOMATIC TRANSFER SWITCHES

Usage:

TEBE3565-00

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02Sep2015

B360
D310
E480
E481
H390
H430
H510

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPAIRING THE CONTROL PANEL ON CERTAIN CTG, AND CTS AUTOMATIC TRANSFER SWITCHES
4469		PS44848

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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 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 "PS44848" 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

30Sep2017

PROBLEM

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Certain CTG, and CTS Automatic Transfer Switches built between July 20, 2015 and August 4, 2015 have improperly installed rivets on the control panel rocker arm.

AFFECTED PRODUCT

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Model	Identification Number
CTG	TSA26036-26040, 26043, 26045, 26049, 26054-26056
CTS	TSG04578

PARTS NEEDED

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Qty	Part Number	Description
1	ZTG000A00004E	Control Panel - See Action Required for ordering
1	ZTG000A00008E	Control Panel - See Action Required for ordering
1	ZTG000A00010E	Control Panel - See Action Required for ordering
1	ZTG000A00020B	Control Panel - See Action Required for ordering
1	ZTG000A00020E	Control Panel - See Action Required for ordering
1	ZTG000A00020F	Control Panel - See Action Required for ordering
1	ZTS000B00010E	Control Panel - See Action Required for ordering
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 Service Manual if/as necessary.

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 Automatic Transfer Switch 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.

Action Required

The control panel will need to be replaced on certain Automatic Transfer Switches (ATS).

Contact Intelligent Switchgear Organization (ISO) for a new power panel. A dealer technician will replace the power panel in the field per the rework instructions in this program. Refer to the attached Rework Procedure.

ISO contact for ordering parts:

Michael Peters
Caterpillar ATS Product Manager
Office: (678) 746-5123
Cellular: (678) 618-0296
Email: mrpeters@CAT-ISO.com

Part number information is listed in the table in Image1.

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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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 3.0-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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Removal:

Step 1: Remove all power connections, noting proper phase rotation.
Step 2: Disconnect cable to controller and generator (note terminal connection points).
Step 3: Remove four (4) mounting nuts (outlined in red), while holding ATS in place.
Step 4: Remove ATS power panel and place on secure surface.
Refer to Image 1.1.1

Image1.1.1

Installation:

Step 1: Install ATS power panel, holding it until secure.
Step 2: Replace four (4) mounting nuts (outlined in red), while holding ATS in place.
Step 3: Connect cable to controller and generator (note terminal connection points).
Step 4: Replace all power connections, noting proper phase rotation.
Refer to Image 1.2.1

Image1.2.1

Testing after reassembly:

It is imperative that each reassembled unit be manually tested before re-installing into the enclosure assembly (if one was provided).

To perform the manual validation test install the manual operating handle into the N-1270 flywheel assembly.

Applying standard operating force, proceed to manually transfer the Automatic Transfer Switch from Position 1 (Source 1) to Position 2 (Source 2). Once the ATS has transferred to Source 2, manually transfer the device back to Source 1.

During each transfer, note that there should be no mechanical binding exhibited by the transfer switch. Also note that during each transfer the SCN/SCE limit switches (57P-1243 / 57P-1242) must be properly activated and deactivated. Failure to activate / deactivate may result in the failure of the device once power has been applied.

Having completed all manual validations tests, proceed to re-install the Automatic Transfer Switch into the enclosure verifying that all electrical connections have been properly executed. For this step, the use of electrical schematics that were provided with the transfer switch is STRONGLY recommended.

Note: The tests referenced below can only be performed if input power to source 1 and source 2 is available. If power is not available STOP HERE. Do not proceed.
Applying power to the transfer switch, proceed to electrically transfer the Automatic Transfer Switch from position 1 (Source 1) to position 2 (Source 2). Once the ATS has been transfer to Source 2, electrically transfer the device back to Source 1.

During each transfer, note that there should be no mechanical binding exhibited by the transfer switch. Also note that during each transfer the SCN/SCE limit switches (57P-1243 / 57P-1242) must be properly activated and deactivated.