PRODUCT SUPPORT PROGRAM FOR UPDATING THE EMCP 4.2 FLASHFILE AND CONFIGURATION SET POINTS ON CERTAIN XQ200 RENTAL GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR UPDATING THE EMCP 4.2 FLASHFILE AND CONFIGURATION SET POINTS ON CERTAIN XQ200 RENTAL GENERATOR SETS

Usage:

TEBE0388-00

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24Sep2013

U-442

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR UPDATING THE EMCP 4.2 FLASHFILE AND CONFIGURATION SET POINTS ON CERTAIN XQ200 RENTAL GENERATOR SETS
4490 7620		PS44028

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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 "PS44028" 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

30Sep2014

PROBLEM

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Voltage selection on certain XQ200 Rental Generator Sets require the use of Electronic Technician (ET) which has proven to be an inconvenience to customers. The existing voltage selector switch can fail on certain XQ200 Rental Generator Sets while operated at full rated load at 208v, 3 phase. If the existing switch fails the power module will be inoperable.

AFFECTED PRODUCT

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Model	Identification Number
C7.1	MRP00100-00127, 129-275

PARTS NEEDED

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Qty	Part Number	Description
1	4443716	SFWR GP-A6001
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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WARNING: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service.

The new EMCP firmware flash file allows for the configuration of the generator to be set individually at a group level. This change along with a permanent setting change to the CDVR will allow voltage selection by the operator without the need of ET. The voltage selector switch on the XQ200 is rated for no more than 631 Amps therefore to protect the switch the EMCP parameter for apparent power at 208V 3 phase operation needs to be updated to 225 KVa.

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, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-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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1. Flash File Update
Update the EMCP firmware flash file to 444-3716 as shown in Image1.1.1. The flash file can be downloaded from SIS Web. Ensure that the computer used has been updated to the latest version of CAT Electronic Technician, 2013B.

Image1.1.1

Prior to the flash the complex software group settings for the unit will look like Image 1.2.1.

Image1.2.1

2. EMCP Settings Update

After installing 444-3716, set the "Generator Connection Configuration #4" to (Single Phase 3-Wire). Also set "Generator Rated Apparent Power #2" to (225 KVa). Values are highlighted in Image 1.3.1.

Image1.3.1

3. CDVR Set Point Update

Use the configuration tool in CAT ET to set the CDVR "Generator Connection Configuration" to (single phase), Image 1.4.1. This setting will remain in single phase for all voltage settings.

Image1.4.1

Now conduct an operational test of the XQ200 unit at all four voltage settings, without making any changes with CAT ET in the EMCP control panel or the CDVR.

NOTE: For 3-phase operation, unplug the two wire connector on the rear of the auxiliary voltage selector switch. For single phase operation, plug in the two wire connector Image 1.5.1.