PRODUCT SUPPORT PROGRAM FOR REPLACING THE CURRENT TRANSFORMERS ON CERTAIN 3516E GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CURRENT TRANSFORMERS ON CERTAIN 3516E GENERATOR SETS

Usage:

TEBE6852-00

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11Dec2017

D-589

O-583

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CURRENT TRANSFORMERS ON CERTAIN 3516E GENERATOR SETS
4476		PS45720

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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 "PS45720" 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

31Dec2018

PROBLEM

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The relatively narrow space between generator set output busbars may cause regional magnetic saturation of transformer core, and subsequently impact the accuracy in current and power factor sensing on certain 3516E Generator Sets.

AFFECTED PRODUCT

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Model	Identification Number
3516E	JH800101-00123
3516E HD	LCK00100-00102, 109-111

PARTS NEEDED

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Qty	Part Number	Description
3	5421737	TRANSFORMER-CURRENT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% 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 the 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, on the product, and in the OMM are not all inclusive. If a tool, procedure, work method, or operating technique 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 and that the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and 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:

Replace the 509-0341 Current Transformers with 542-1737 Current Transformers which are the same dimension but has more core material. This will improve CT's capability in capturing flux and avoid regional magnetic saturation.

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%
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-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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Prior to the rework, put the generator set in STOP mode and open the circuit breaker. Please eliminate any possibility that can cause live voltage and/or current on the busbars before implementing this rework procedure.

Remove the 12 fasteners from the busbar cover on front panel, and remove the busbar cover, as shown in Image 1.1.1.

Image1.1.1

Remove the 4 fasteners from the bottom guard on front panel, and remove the guard, as shown in Image 1.2.1.

Image1.2.1

Remove fasteners from insulators, as shown in Image 1.3.1.

Image1.3.1

Remove 3 insulators, as shown in Image 1.4.1.

Image1.4.1

Remove 12 fasteners connecting T4, T5 and T6 busbars to neutral bar, as shown in Image 1.5.1.

Image1.5.1

Remove neutral bar, as shown in Image 1.6.1.

Image1.6.1

Remove 6 CT support fasteners from T4, T5 and T6 busbars, as shown in Image 1.7.1.

Image1.7.1

Remove the CT assembly from busbars, as shown in Image 1.8.1.

Image1.8.1

Remove the 12 fasteners connecting current transformers to mounting plate, as shown in Image 1.9.1.

Image1.9.1

Replace current transformers 509-0341 with 542-1737. Ensure polarity direction matches old current transformers, as shown in Image 1.10.1.

Image1.10.1

Install the 12 fasteners to connect current transformers to mounting plate. Tighten the bolts to 6 Ft-Lb(8 N-m) in cross pattern, as shown in Image 1.11.1.

Image1.11.1

Install current transformer assembly to T4, T5 and T6 busbars, as shown in Image 1.12.1.

Image1.12.1

Install the 6 fasteners to fix the current transformer assembly to T4, T5 and T6 busbars. Tighten the bolts to 25 Ft-Lb(34 N-m), as shown in Image 1.13.1.