PRODUCT SUPPORT PROGRAM FOR REWORKING THE FAN MOTOR ELECTRICAL CABLES ON CERTAIN PM3516 POWER MODULES
Usage:
TEBE0560-00
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| 12Dec2013 |
U-629
A-434
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| Before/After | PRODUCT SUPPORT PROGRAM FOR REWORKING THE FAN MOTOR ELECTRICAL CABLES ON CERTAIN PM3516 POWER MODULES |
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| 4459 5927 | PS44127 |
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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 "PS44127" 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 |
| 31Dec2015 |
PROBLEM
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| The existing fan motor cable connections on certain PM3516 Power Modules can fail. If the existing cable lug insulation fails contact with the surface of the electrical connection box can cause a short. Once this occurs the Power Module will no longer be operable. |
AFFECTED PRODUCT
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| Model | Identification Number |
| PM3516 | KEN00100-00101, 103-104, 106-113, 115-137, 139, 141, 144-157, 160-165, 167-168, 171-172, 175-178, 180-181, 183, 185-188, 191, 193-208, 210-220, 222-223, 231-232 NAM00100-00101, 103, 105-115, 117-122, 124-130, 132-142, 144-145, 147-153, 156-158, 162-164, 166, 168-171, 173-174, 178-180, 182-185, 187, 189-190, 195-196, 198-199 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 1 | 3665089 | SPLICE-MOTOR |
| 1 | 3665090 | SPLICE-MOTOR |
| 1 | BLACK | VINYL ELECTRICAL TAPE |
| 1 | BROWN | VINYL ELECTRICAL TAPE |
| 1 | ORANGE | VINYL ELECTRICAL TAPE |
| 1 | YELLOW | VINYL ELECTRICAL TAPE |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 27% 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. |
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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 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 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. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine. An area of improvement needs to be addressed in order to prevent possible failure of the fan motor cables. The rework procedure includes the inspection of the insulation around the fan motor cable ends and installation details of splice kits if found necessary. Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework. |
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SERVICE CLAIM ALLOWANCES
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0-24 mo |
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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. |
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| Remove the cover from fan motor electrical connection box. Inspect all cable terminations T1-T6. If only electrical vinyl tape is present to insulate the ends and rubber lug covers are missing please continue with the rework procedure. If covers have been added then do not continue with the rework procedure. Refer to Image1.1.1. |
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| Image1.1.1 |
| Mark the cables to indentify each phase before removing tape. Remove electrical tape from T1, T2, T3 connections. Check that the hardware used to join the cable lugs are securely tightened to 8.8 +/- 2.2 ft-lbs (12 +/- 3 Nm). |
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| Image1.2.1 |
| Apply a mastic strip from the splice kit around the cable insulation before it meets the lug as shown in Image1.3.1. Repeat for all phases. Part Required: 1 366-5090 Splice Kit |
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| Image1.3.1 |
| Apply silicon grease on top of mastic strip to help the lug cover slide easily. |
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| Image1.4.1 |
| Install a lug cover for each phase. |
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| Image1.5.1 |
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| Image1.5.1 |
| Use color electrical tape to securely wrap the lug cover to prevent it from falling off. Follow the NEC convention for 480 three phase Brown/Orange/Yellow to color code the ends. Parts Required: Electrical Tape (Brown) Electrical Tape (Orange) Electrical Tape (Yellow) |
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| Image1.6.1 |
| Repeat all steps for remaining T4, T5, T6 connections. Image1.7.1. Install electrical box cover. The Power Module can now be returned to service Parts Required: 3665089 Splice Kit Electrical Tape (Black) |
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