PRODUCT IMPROVEMENT PROGRAM FOR UPGRADING THE 600VAC ARTIC COLD WEATHER PACKAGING ON CERTAIN XQ230 AND XQ300 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR UPGRADING THE 600VAC ARTIC COLD WEATHER PACKAGING ON CERTAIN XQ230 AND XQ300 GENERATOR SETS

Usage:

REBE7063-00

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17May2011

U-199

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR UPGRADING THE 600VAC ARTIC COLD WEATHER PACKAGING ON CERTAIN XQ230 AND XQ300 GENERATOR SETS
1409 1417 4469 1408		PI10853

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10853" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10853" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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PROBLEM

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The existing 600VAC Arctic Cold Weather packaging controls feature has an incorrect transfer switch configuration, an incorrect 600VAC transformer wiring and an unbalanced load distribution center. This may cause a shock hazard and, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
C9	X3R01202-01206, 1212-1219

PARTS NEEDED

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Qty	Part Number	Description
1	SWITCH	NON-CATERPILLAR DEALER SUPPLIED SWITCH
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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 Rework Procedure for action required details.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR UPGRADING THE 600VAC ARTIC COLD WEATHER PACKAGING ON CERTAIN XQ230 AND XQ300 GENERATOR SETS

MODELS INVOLVED - XQ230 and XQ300 Generator Sets

Dear Caterpillar Product Owner:

The existing 600VAC Arctic Cold Weather packaging controls feature has an incorrect transfer switch configuration, incorrect 600VAC transformer wiring and an unbalanced load distribution center which may cause a shock hazard and, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

The existing transfer switch must be removed and replaced, the 600VAC transformer wiring must be corrected and the load distribution center must be reconfigured.

You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 17May2011 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 17May2011 Service Letter

Rework Procedure

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Step 1 - Isolate the generator set before commencing any work on the unit, open generator set breaker, activate the emergency stop, disconnect all shore power connections and disconnect battery cables.

Ensure all health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out the generator before commencing any type of work.

Only qualified repair personnel should service this equipment.

Step 2 ? The appropriate Caterpillar dealership representative working this service program is to contact the following Enercon representative in order to receive appropriate instructions regarding:

Delivery coordination of the replacement transfer switch and the return shipment instructions for the original transfer switch.

Enercon
Project Management - Engineering
490 Industrial Rd.
Barnesville, GA 30204
(770) 358-8889, ext. 4108

Step 3 - The Caterpillar dealership is to arrange for the removed transfer switch to be shipped back to the following address via the instructions provided by Enercon. The transfer switch is to be sufficiently re-packaged to prevent any shipping damage.

Step 4 ? Open the enclosure cover for the existing transfer switch assembly.

Step 5 ? Identify and label each of the individual conductors.

Step 6 ? Disconnect all of the individual conductors. Refer to Image1.5.1.

Image1.5.1

Step 7 ? Disconnect the exterior conduit connected to the transfer switch enclosure assembly. Refer to Image1.6.1.

Image1.6.1

Step 8 ? Remove and retain the transfer switch enclosure mounting hardware.

Step 9 ? Remove the transfer switch assembly from the generator set canopy.

Step 10 ? Secure the new transfer switch assembly to the generator set canopy utilizing the hardware from Step 8 and reconnect the exterior interconnecting conduit.
Note: The exterior conduit containing the transfer switch conductor?s must be passed through the new transfer switch enclosure and align with the secondary exterior control panel. Refer to Image1.6.1.

Step 11 ? Connect the transfer switch wiring as per the following wiring diagram.
Refer to Image1.9.1 and Image1.9.2.

Notes:
1. Add individual conductors as required. Ensure compliance with the required AWG for each conductor as specified in Image1.9.1.
2. Ensure that the 600VAC transformer is wired according to Image1.9.1.
3. Ensure that the shore power load distribution panel is properly interfaced with the transfer switch according to Image1.9.1.

Image1.9.1

Image1.9.2

Step 12 ? Secure exterior cover to the new transfer switch assembly.

Step 13 ? Locate the 600VAC Transformer. Refer to Image1.11.1.

Image1.11.1

Step 14 ? Disconnect the individual external conductors terminated at the transformer.

CAUTION: Before proceeding with the removal and installation of the transformer assembly, ensure adequate lifting and support devices are available or additional manpower is available to assist with the removal of the transformer.

Step 15 ? Remove the 600VAC transformer from the uni-strut bracket affixed to the enclosure wall. Place the transformer in a location and in a position to access the bottom cover plate.

Step 16 ? Remove the bottom cover plate of the transformer cover.

Step 17 ? Using a 8 AWG green color coded conductor of sufficient length, connect one end of the conductor at the X2-X3 transformer termination point and connect the opposing conductor end to the grounding stud on the transformer case.
Use a Ring Terminal to connect the conductor to the grounding stud and use an appropriately sized wire nut to secure the X2, X3 and ground conductors together.
Refer to Image1.9.1 and Image1.13.1.

Image1.13.1

Step 18 ? Install the bottom transformer cover plate.

Step 19 ? Install the transformer back on the uni-strut brackets affixed to the enclosure wall and properly secure into place.

Step 20 - Reconnect the individual external conductors from Step 14. Refer to Image1.9.1.

Step 21 ? Locate the shore power load distribution panel and remove the access cover.
Refer to Image1.15.1.

Image1.15.1

Step 22 ? Confirm that the load center is properly balanced in accordance with the following wiring diagram. Reconfigure as required. Refer to Image1.16.1.

Image1.16.1

Step 23 - Install the cover for the shore power load center access panel.

Step 24 ? Confirm the operation and the functionality of arctic cold weather controls.

Step 25 - Restore the generator set to its proper operational condition.