SEAL-O-RING 2H3927 - Caterpillar

REBE6237-00
02Aug2010
U-294
Before/After
PRODUCT SUPPORT PROGRAM FOR REWORKING THE ASR RELAY ON CERTAIN PM3516, XQ2000 POWER MODULES WITH AUTO PARALLELING CONTROLS
4459 4460 7426 PS43132
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 "PS43132" as the Part Numberand "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.
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
31Aug2013
PROBLEM
The existing ASR relay is used to open the generator breaker when operating in AUTO mode and the unit is signaled to stop. Occasionally the ASR relay will fail to drop-out. When this happens it will affect the operation in one of two possible ways:
1. If operating in either single unit-stand alone mode or in island mode paralleling, then the engine will go into cooldown/stop but the generator breaker will remain closed until the engine reaches zero RPM.
2. If operating in utility mode paralleling, then the engine will go into pre-cooldown(continuing to baseload), will not ramp down, and the generator breaker will remain closed.
AFFECTED PRODUCT
Model Identification Number
PM3516 KEN00105, 110, 164, 167-174, 176-177, 179-180, 182, 184, 188-192, 194-197, 203-204, 206, 208-209, 211-212, 214-216, 219, 221, 223-232
NAM00107-00108, 112-114, 116-130, 133
PARTS NEEDED
Qty
Part Number Description
100 8T7875 WIRE
1 2250547 BLOCK-TERMINAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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
Steps need to be taken to correct the ASR relay drop-out issue.
1. Rework of certain wiring to the ASR relay.
2. Perform verification test.
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%
0-5000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
XQ2000 Auto Paralleling Control Box (Image1.1.1)
Image1.1.1
REWORK PROCEDURE
1. Install a new 225-0547 Terminal Block and label as "DI2". This requires making a space between existing terminals 'AP6' and 'AP7' then inserting the new terminal block in this space. Location of terminal strip is shown in Image1.2.1.
Image1.2.1
2. Wire #F406-AU206 (from EMCP 3 pin #55 to terminal 'AP7') must be moved from terminal 'AP7' to new terminal 'DI2'.
3. Wire #T981-RE162 going to relay 'ASR' shown in Image1.3.1 must be removed from 'ASR-24', re-routed, and brought to 'ASR-A2'.
Image1.3.1
4. Install new 100cm 16AWG black wire 8T-8730 from relay ASR-24 to new terminal 'DI2' and label as #F401,
Verification Testing
Refer to the Image 1.4.1 for the location