Procedure for Replacing the Circuit Breaker Group on Certain Generator Sets{1420, 4461} Caterpillar

Procedure for Replacing the Circuit Breaker Group on Certain Generator Sets{1420, 4461}

Usage:

D336 09A

Electric Power Generation:: SR4 (S/N: 5CA1-UP; 5DA1-UP; 5EA1-UP; 5FA1-UP; 5GA1-UP; 5HA1-UP; 5JA1-UP; 5KA1-UP; 5LA1-UP; 5MA1-UP; 5NA1-UP; 5RA1-UP; 5TA1-UP; 5UA1-UP; 5VA1-UP; 5YA1-UP; 6BA1-UP; 6CA1-UP; 6DA1-UP; 6EA1-UP; 6FA1-UP; 6HA1-UP; 6JA1-UP; 6MA1-UP; 6NA1-UP; 6PA1-UP; 6WA1-UP; 2WD1-UP; 5TD1-UP; 8JF1-UP; 8KF1-UP; 8LF1-UP; 9EF1-UP; 9FF1-UP; 9GF1-UP; 6CG1-UP; 6DG1-UP; 6EG1-UP; 8HG1-UP; 9FG1-UP; 3KJ1-UP; 4SJ1-UP; 5NJ1-UP; 6EJ1-UP; 7AJ1-UP; 2MM1-UP; 3YM1-UP; 4LM1-UP; 5JM1-UP; 6JM1-UP; 6YR1-UP; 7YR1-UP; 8DR1-UP; 8ER1-UP; 9CR1-UP; 9DR1-UP; 1MS1-UP; 7RS1-UP; 7SS1-UP; 7TS1-UP; 7WS1-UP; 7XS1-UP; 7YS1-UP); SR4B (S/N: 6PK1-UP; 8GK1-UP; 7GM1-UP; 1BN1-UP; 3EN1-UP; 3GN1-UP; 3HN1-UP; 4WN1-UP; 5WN1-UP; 9EN1-UP; 8GW1-UP; 8EZ1-UP; 8LZ1-UP; 9AZ1-UP); XQ200 (S/N: LEA1-UP)
Engine:: 3306 (S/N: 66D1-UP; 70R1-UP); 3306B (S/N: B8D1-UP); 3408 (S/N: 67U1-UP; 78Z1-UP); 3408B (S/N: 67U1-UP; 78Z1-UP); 3408C (S/N: 67U1-UP; 78Z1-UP); 3412 (S/N: 9XF1-UP; 2WJ1-UP; 38S1-UP; 81Z1-UP); 3412C (S/N: BAK1-UP; 5FL1-UP; DJN1-UP; 9EP1-UP; TFT1-UP; BCW1-UP; RTY1-UP; 81Z1-UP); 3412E (S/N: TGC1-UP); 3508 (S/N: CAW1-UP; 23Z1-UP; 70Z1-UP); 3508B (S/N: 4GM1-UP; BGX1-UP); 3512 (S/N: 6PM1-UP; FDR1-UP; 24Z1-UP; 67Z1-UP); 3512B (S/N: BLF1-UP); 3516 (S/N: 4XF1-UP; 7KM1-UP; GZX1-UP; 25Z1-UP; 73Z1-UP); 3516B (S/N: GZT1-UP; GZY1-UP); D333C (S/N: 09A1-UP; 66D1-UP; 70R1-UP); D334 (S/N: 92B1-UP); D343 (S/N: 62B1-UP); G3406 (S/N: 4FD1-UP; R7E1-UP; KAR1-UP); G3408 (S/N: 6NB1-UP); G3412 (S/N: R7A1-UP; 7DB1-UP; KAP1-UP); G3508 (S/N: CPJ1-UP; CPS1-UP); G3512 (S/N: CRN1-UP); G3516 (S/N: ZBA1-UP; 25Z1-UP); G3516B (S/N: ZBB1-UP; ZBC1-UP); G3516C (S/N: GSB1-UP; GZZ1-UP)
Generator Set:: 3406B GEN SET (S/N: 4PM1-UP); 3406C GEN SET (S/N: KPS1-UP); 3412C GEN SET (S/N: BAX1-UP); 3456 GEN SET (S/N: CCB1-UP; CBX1-UP)
Industrial Engine:: 3406 IND (S/N: 90U1-UP); 3412C IND (S/N: 38S1-UP)

Introduction

This Special Instruction will guide you through removing and replacing the CK-frame breakers with the P-frame breakers. This procedure is designed to utilize most of the existing components from the original factory installed system on the Generator Set. Certain circumstances such as replacing the shunt trip and auxiliary contact will require the replacement of the entire breaker.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

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 and on the product. 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 and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

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Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Cat dealer for replacement manuals. Proper care is your responsibility.

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Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10 ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death

Preparation for the Replacement

Note: In order to replace the circuit breaker, the Generator Set must already have a factory installed CK-frame breaker.

Turn off the Generator Set. Lock out and tag out the Generator Set.

Remove the breaker cover.

Disconnect all power cables from the breaker.
Note: Ensure that the cables are properly marked for reinstallation.

Remove the breaker from the bracket.
Note: The bracket may be removed along with breaker if desired. Disconnect all electrical accessories.

Remove bus bars from breaker and retain for reinstallation on the new breaker.

Modifying the Bracket for the New P-Frame Breaker

Refer to Table 1 for the correct circuit breaker group to replace the existing part number.

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Table 1
Existing Part Number	Replacement Part Number
104-7632	270-4534
104-7633	270-4535
104-7634	270-4536
104-7635	270-4537
105-6550	270-4534
112-3509	270-4543
112-3517	270-4543
126-6154	270-4590
183-1872	270-4608
183-1873	270-4609
183-1874	270-4610
183-1875	270-4611
198-1931	265-4714
201-0277	270-4614
201-0278	270-4615
201-0279	270-4616
201-0280	270-4617
201-0291	270-4599
201-0292	270-4668
201-0293	270-4621
201-0294	270-4622
205-8209	270-4537
300-1825	270-4534

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Illustration 1	g02556241
(A) 65 mm (2.56 inch) (B) 26.3 mm (1.04 inch) (C) 66.3 mm (2.61 inch) (1) Existing holes (2) New holes

Identify the location for the new holes to be drilled in the bracket. Refer to Illustration 1.

Mark and drill the new holes using a 6 mm (0.25 inch) drill bit.

Touch up the new mounting holes with paint.

Modifying the Cover Group for the New P-Frame Breaker and Installing the New Breaker

Remove the rubber boot from the cover (if equipped).

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Illustration 2	g02518718
(D) 25 mm (1 inch) (3) Material to be removed (4) Existing breaker hole

The following procedure is applicable for all generator sets except generator number prefixes S/N:KAP, ; S/N:KAR, and ; S/N:KPS. For Generator Sets with serial number prefixes ; S/N:KAP, ; S/N:KAR, and ; S/N:KPS proceed to Step 6. All other prefixes must outline the new opening for the cover using the dimensions in Illustration 2.

Cut the new rectangular opening using the necessary tooling.

Smooth the sharp edges and paint the area around the new opening.

Mount the new P-frame breaker onto the modified bracket using the hardware provided with the new breaker. Reposition the mounting bracket to ensure that the cover is aligned with the front face of the breaker. Proceed to Step 10.

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Illustration 3	g02540005
Configuration 1 (E) 190 mm (7.48 inch) (F) 57.8 mm (2.28 inch) (G) 212 mm (8.35 inch) (H) 101.4 mm (4 inch) (J) 74 mm (2.91 inch) (K) 104.5 mm (4.11 inch) (3) Material to be removed (4) Existing breaker hole

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Illustration 4	g02540264
Configuration 2 (L) 190 mm (7.48 inch) (M) 46.3 mm (1.82 inch) (N) 212 mm (8.35 inch) (P) 80 mm (3.15 inch) (Q) 98 mm (3.85 inch) (R) 132 mm (5.20 inch) (3) Material to be removed (4) Existing breaker hole

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Illustration 5	g02540299
Configuration 3 (S) 190 mm (7.48 inch) (T) 65.5 mm (2.58 inch) (U) 212 mm (8.35 inch) (V) 97.3 mm (3.80 inch) (W) 79 mm (3.11 inch) (X) 108.6 mm (4.28 inch) (3) Material to be removed (4) Existing breaker hole

If the Generator Sets have serial number prefix S/N:KAP, ; S/N:KAR, or ; S/N:KPS, identify which Illustration to use based on the dimensions of the opening. For a 98 mm (3.85 inch) x 132 mm (5.20 inch) opening use Illustration 4. For a 79 mm (3.11 inch) x 108.6 mm (4.28 inch) opening use Illustration 5, and for a 74 mm (2.91 inch) x 104.5 mm (4.11 inch) opening use Illustration 3.