Circuit Breakers Need To Be Inspected On Certain 3208, 3304, 3304B, G3306, 3306, 3306B, 3406, 3406C, 3408B, 3408C, 3412, Generator Sets Caterpillar

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1409" as the Part Number, "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 "PI1409" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Problem

A potentially hazardous condition has been identified with certain 300-630 Amp "CJ" labeled circuit breakers installed on engine generator sets. A failure of internal componentry can lead to the failure of the entire breaker if tripped while under load, possibly leading to serious personal injury or death.

Affected Product
Model & Identification Number

3208 (30A7082-7090, 30A7096-7099, 30A7155, 30A7159, 30A7164, 30A7171-7172, 30A7197-7198, 30A7200-7203, 30A7206-7208, 30A7211-7213, 30A7231, 30A7233, 30A7238-7241, 30A7254-7255, 30A7257, 30A7277, 30A7280, 30A7286-7288, 30A7290-7292, 30A7309, 30A7311-7315 5YF3673-3674 , 5YF3729, 5YF3733, 5YF3739, 5YF3761-3762, 5YF3764, 5YF3767, 5YF3772-3774, 5YF3778, 5YF3784-3785, 5YF3787, 5YF3789, 5YF3794, 5YF3797, 5YF3799-3800, 5YF3802-3803, 5YF3805, 5YF3811-3812, 5YF3815-3817, 5YF3820-3823, 5YF3826, 5YF3832, 5YF3840-3843, 5YF3845, 5YF3850-3856, 5YF3858-3862, 5YF3867, 5YF3875, 5YF3878-3882, 5YF3887-3892)

3304 (83Z10566, 83Z10595, 83Z10634, 83Z10649-10650, 83Z10735, 83Z10770, 83Z10792, 83Z10796, 83Z10824, 83Z10887-10888, 83Z10908, 83Z10945, 83Z10964-10965, 83Z10967, 83Z10972-10973, 83Z11022, 83Z11056, 83Z11082-11084, 83Z11116, 83Z11148, 83Z11159, 83Z11170)

3304B (9HK368, 9HK375-393, 9HK395-417, 9HK420-421, 9HK423-479)

3306 (85Z14267-14268)

3306B (8JJ400-401, 8JJ403-444, 8JJ447-511, 8JJ514 9NR2438 , 9NR2443-2445, 9NR2448, 9NR2452-2456, 9NR2459, 9NR2465-2466, 9NR2468-2470, 9NR2489-2491, 9NR2494-2496, 9NR2509, 9NR2513-2515, 9NR2517, 9NR2522, 9NR2524-2525, 9NR2527-2533, 9NR2536, 9NR2539-2543, 9NR2545-2549, 9NR2553-2554, 9NR2560, 9NR2562-2565, 9NR2571, 9NR2574, 9NR2581, 9NR2583-2586, 9NR2588-2590, 9NR2593, 9NR2595-2596, 9NR2598-2601, 9NR2604-2607, 9NR2610-2614, 9NR2616, 9NR2619-2622, 9NR2624-2625, 9NR2629-2632, 9NR2635, 9NR2637, 9NR2640, 9NR2643, 9NR2646, 9NR2654-2657, 9NR2659, 9NR2661-2662, 9NR2667, 9NR2671, 9NR2678-2681, 9NR2685-2687, 9NR2689, 9NR2692, 9NR2694-2700, 9NR2702-2703, 9NR2706-Up9NR2707, 9NR2709, 9NR2711, 9NR2716-2719, 9NR2723, 9NR2726-2729, 9NR2736, 9NR2744-2747, 9NR2750, 9NR2754, 9NR2761-2765, 9NR2769, 9NR2771, 9NR2777, 9NR2784-2785, 9NR2792-2793, 9NR2815, 9NR2821, 9NR2823-2824, 9NR2827, 9NR2830-2834, 9NR2836, 9NR2838, 9NR2841, 9NR2850-2853, 9NR2855-2856, 9NR2861, 9NR2864-2866, 9NR2871, 9NR2880, 9NR2889-2892, 9NR2894-2896, 9NR2898, 9NR2900-2902, 9NR2904-2905, 9NR2907-2908, 9NR2919-2920, 9NR2922, 9NR2934, 9NR2952, 9NR2955, 9NR2963-2966, 9NR2969, 9NR2971-2973, 9NR2975, 9NR2977, 9NR2979, 9NR2981-2982, 9NR2986, 9NR2993-2994, 9NR3002-3013, 9NR3030-3031, 9NR3033-3037, 9NR3040-3048, 9NR3050-3054, 9NR3057-3058, 9NR3060-3063, 9NR3067-3072, 9NR3074, 9NR3076-3080, 9NR3082-3085, 9NR3088-3090, 9NR3092-3094, 9NR3096, 9NR3098, 9NR3101, 9NR3106-3107, 9NR3111, 9NR3113, 9NR3116, 9NR3119 , 9NR3122-3123, 9NR3126-3127, 9NR3129, 9NR3131-3134, 9NR3137, 9NR3139, 9NR3144, 9NR3147, 9NR3151, 9NR3156, 9NR3160, 9NR3166-3167, 9NR3174, 9NR3178-3184, 9NR3186-3190, 9NR3192-3193, 9NR3195-3196, 9NR3198-3199, 9NR3202, 9NR3207, 9NR3209, 9NR3214-3215, 9NR3222, 9NR3233, 9NR3235-3239, 9NR3241, 9NR3247, 9NR3249-3250, 9NR3256, 9NR3263-3264, 9NR3266-3267, 9NR3271-3272, 9NR3274-3275, 9NR3278-3279, 9NR3282, 9NR3287-3291, 9NR3293, 9NR3295, 9NR3297, 9NR3299-3300, 9NR3303-3304, 9NR3306-3307)

G3306 (07Y6756)

3406 (4FD1567, 4FD1577, 4FD1587, 4FD1590, 4FD1596, 4FD1601, 4FD1631, 4FD1638, 4FD1643, 4FD1655, 4FD1758, 4FD1766, 4FD1783, 4FD1787, 4FD1795, 4FD1804, 4FD1835-1837, 4FD1848-1855, 4FD1869, 4FD1872-1875, 4FD1877-1879, 4FD1883-1884, 4FD1887, 4FD1889, 4FD1891, 4FD1893, 4FD1895, 4FD1899, 4FD1902)

3406C (4ZR3443, 4ZR3445, 4ZR3449, 4ZR3452, 4ZR3464, 4ZR3476, 4ZR3478-3480, 4ZR3483, 4ZR3489, 4ZR3498-3499, 4ZR3504-3505, 4ZR3508, 4ZR3510-3512, 4ZR3515, 4ZR3518, 4ZR3520, 4ZR3534, 4ZR3548-3549, 4ZR3552, 4ZR3555-3557, 4ZR3560-3562, 4ZR3564, 4ZR3567-3568, 4ZR3589-3590, 4ZR3592, 4ZR3599, 4ZR3602-3604, 4ZR3611, 4ZR3613, 4ZR3618, 4ZR3620, 4ZR3622, 4ZR3624, 4ZR3628, 4ZR3633, 4ZR3636, 4ZR3642, 4ZR3644-3650, 4ZR3653-3654, 4ZR3656, 4ZR3659-3660, 4ZR3665-3666, 4ZR3669, 4ZR3672, 4ZR3676, 4ZR3679, 4ZR3682, 4ZR3685, 4ZR3687, 4ZR3689-3696, 4ZR3700-3702, 4ZR3704-3706, 4ZR3709, 4ZR3711-3713, 4ZR3715-3716, 4ZR3719-3721, 4ZR3723, 4ZR3725-3727, 4ZR3734-3744, 4ZR3748-3749, 4ZR3753, 4ZR3761-3763, 4ZR3770, 4ZR3777-3780, 4ZR3798, 4ZR3811, 4ZR3818, 4ZR3828, 4ZR3839, 4ZR3846, 4ZR3849-3853, 4ZR3855, 4ZR3856-3859, 4ZR3862, 4ZR3866-3868, 4ZR3870-3871, 4ZR3873, 4ZR3875, 4ZR3878, 4ZR3882, , 4ZR3890-3893, 4ZR3897, 4ZR3900, 4ZR3902, 4ZR3904-3907, 4ZR3911, 4ZR3915-3916, 4ZR3921, 4ZR3933, 4ZR3935, 4ZR3941, 4ZR3949-3951, 4ZR3964-3965, 4ZR3967, 4ZR3970, 4ZR3972-3974, 4ZR3981, 4ZR3983-3984, 4ZR3989, 4ZR3991-3994, 4ZR3996, 4ZR3998-3999, 4ZR4009-4011, 4ZR4013, 4ZR4015-4016, 4ZR4021-4022, 4ZR4026-4029, 4ZR4033-4047, 4ZR4049, 4ZR4054, 4ZR4056-4058, 4ZR4066, 4ZR4068, 4ZR4072-4074, 4ZR4081, 4ZR4084-4087, 4ZR4090-4092, 4ZR4094, 4ZR4097-4098, 4ZR4100-4101, 4ZR4103, 4ZR4108, 4ZR4110, 4ZR4122, 4ZR4125, 4ZR4130, 4ZR4138, 4ZR4155-4156, 4ZR4158, 4ZR4161-4163, 4ZR4167-4168, 4ZR4170-4171, 4ZR4180-4182, 4ZR4185, 4ZR4190, 4ZR4196, 4ZR4199, 4ZR4205-4206, 4ZR4208-4210, 4ZR4212-4213, 4ZR4222, 4ZR4232, 4ZR4254, 4ZR4259-4261, 4ZR4263-4267, 4ZR4270-4272, 4ZR4275-4277, 4ZR4281-4282, 4ZR4285, 4ZR4287, 4ZR4289-4290, 4ZR4294, 4ZR4296, 4ZR4299, 4ZR4302-4304, 4ZR4306, 4ZR4308-4310, 4ZR4312, 4ZR4314-4315, 4ZR4318-4319, 4ZR4323-4324, 4ZR4326, 4ZR4331-4332, 4ZR4334-4337, 4ZR4344-4345, 4ZR4351, 4ZR4358, 4ZR4361-4362, 4ZR4364, 4ZR4367-4368, 4ZR4373-4374, 4ZR4376, 4ZR4391, 4ZR4397, 4ZR4400-4401, 4ZR4407, 4ZR4409, 4ZR4415-4416, 4ZR4418-4420, 4ZR4423, 4ZR4432-4434, 4ZR4442-4445, 4ZR4447, 4ZR4450, 4ZR4459, 4ZR4462-4464, 4ZR4468, 4ZR4477, 4ZR4486, 4ZR4491, 4ZR4497, 4ZR4506, 4ZR4509, 4ZR4512-4513, 4ZR4517, 4ZR4519, 4ZR4531-4532, 4ZR4534, 4ZR4536, 4ZR4538, 4ZR4546, 4ZR4548-4549, 4ZR4551, 4ZR4553, 4ZR4559, 4ZR4561, 4ZR4563, 4ZR4577, 4ZR4580, 4ZR4584, 4ZR4587-4588, 4ZR4593, 4ZR4595-4597, 4ZR4599, 4ZR4601 , 4ZR4615, 4ZR4617, 4ZR4624-4625, 4ZR4627, 4ZR4629, 4ZR4633, 4ZR4635, 4ZR4641-4642, 4ZR4644-4645, 4ZR4649, 4ZR4651-4653, 4ZR4655-4657, 4ZR4660, 4ZR4662, 4ZR4664-4666, 4ZR4668-4669, 4ZR4671-4672, 4ZR4676, 4ZR4681-4683, 4ZR4688, 4ZR4692, 4ZR4695, 4ZR4698, 4ZR4701-4705, 4ZR4726-4733, 4ZR4736, 4ZR4739-4740, 4ZR4745, 4ZR4747-4748, 4ZR4757, 4ZR4759, 4ZR4763, 4ZR4766, 4ZR4771, 4ZR4776, 4ZR4779, 4ZR4783, 4ZR4785-4791, 4ZR4796-4798, 4ZR4807-4808, 4ZR4812, 4ZR4820 1LS541 , 1LS543-550, 1LS556, 1LS561-562, 1LS564, 1LS574, 1LS588, 1LS592-595, 1LS609-614, 1LS617, 1LS621, 1LS623, 1LS625-626, 1LS634, 1LS651, 1LS654, 1LS663, 1LS665-666, 1LS669, 1LS672-675, 1LS684-685, 1LS700, 1LS704-705 2WB17952 , 2WB17954, 2WB17956-17957)

3408B (6NB1710, 6NB1719, 6NB1722, 6NB1727-1730, 6NB1732, 6NB1734, 6NB1743, 6NB1760-1762, 6NB1764-1765, 6NB1774, 6NB1776-1777, 6NB1779, 6NB1783, 6NB1835, 6NB1837, 6NB1857, 6NB1865, 6NB1868-1869)

3408C (78Z5870-5871)

3412 (7DB1431-1432, 7DB1457 2WJ1871 , 2WJ1912, 2WJ1930-1931, 2WJ2036 81Z22206 , 81Z22395, 81Z22424, 81Z22426, 81Z22677, 81Z22738, 81Z22899, 81Z22904, 81Z23137, 81Z23292, 81Z23310, 81Z23363, 81Z23421)

Parts Needed

Contact EPG Service to have an inspection tool shipped out to dealership to perform inspection process.

Provide Dealership Number, Contact name, mailing address and phone number.

(309) 578-3694 or (309) 578-6795

Outside North America you could also email above information to:

Action Required

See the attached Rework Procedure.

Owner Notification

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

Service Claim Allowances

All units inspected must have the breaker date codes recorded in the Claims record.

Parts Disposition

For breakers found to be defective outside of North America, Dismantle the cover plate and return only the cover plate for claim approval, making the rest of the breaker inoperable and scrap.

Return all Circuit Breakers that do not pass this inspection process to:

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

Attach.

(1-Copy of Owner Notification For U.S. And Canadian Owners

(2-Rework Procedure

Copy of Owner Notification For U.S. And Canadian Owners

Rework Procedure

Before performing inspection and possibly replacement of the Circuit breaker, you must read and understand the following safety instructions. After reading the instructions, inspect the breaker to see if it is within the affected date code ranges. If the breaker falls within both of these ranges, then the breaker needs to be inspected for the following potential errors; missing or misoriented internal fibers, and/or missing arc chute stacks. If any of those conditions are found to be present, the breaker must then be replaced.

DANGER Hazard of Electrick Shock, Burn, or Explosion!

* This equipment must be installed and serviced by qualified electrical personnel only.

* Turn off all power supplying this equipment before working on or inside equipment.

* Always use a properly rated voltage sensing device to confirm power is off.

* Replace all devices, doors, and covers before turning on power to this equipment.

* It is important to utilize appropriate personal protective devices such as approved safety glasses, and rated safety gloves.

Before beginning any of the following procedures, the electrical supply feeding the breaker must be disconnected and safely secured so that there is no voltage to the breaker on either load or supply side.

For package gensets the terminal box side cover needs to be removed to access the breaker to perform the necessary procedures of this service letter. For XQ rental packages the ten bolts holding the sheet metal cover over the back of the breakers needs removed to gain access to circuit breakers to view date codes and possibly remove the breaker for further inspection (there are two breakers affected on XQ125).

INSPECTION:

A. Inspect for Date Codes Involved:

There are two date codes on the product. This notice applicable ONLY to breakers that are within both the manufactured date code range of 98041. The date codes are described below.

* The Manufacturing date code label is located on the right side of the device near the ON end. The label will have a small six-digit number and a large five-digit number. The five digit number is the manufacturing date code. The first digit is a letter code for internal use; the next four digits identify the year and week of manufacture.

The Manufacturing date code is identified as follows:

The affected manufacturing date odes are : 9803 through 9838

* The Assembly date code label is located on the right side of the device near the OFF end. This label will have "Assembled in USA" and a five-digit number. The five-digit number is the assembly date code. The first two numbers are the year of assembly, the next two digits are week of assembly, and the last digit is the day.

The affected assembly date codes are: 98041 through 98447

If the circuit breaker does not fall within both sets of date codes the breaker is not affected and can be returned to service. If it is within both date code ranges proceed to Step B. For XQ rental units, remove the breaker(s) from the panel to be able to perform inspections.

NOTE: Record the date codes of circuit breakers inspected and file with claim.

Illustration 1.

NOTE: The following inspection procedures must be performed on each line side pole of the circuit breaker, at the ON end.

B. Probe Inspection of Affected Breakers For videotape of the following procedure refer to POWER CONNECTION Broadcast of April 21, 1999.

1. Turn off all power supplying this equipment before working on or inside the equipment. Verify power is off using a properly rated voltage meter.

2. Remove the lug covers at the lin end of the circuit breaker by unscrewing the two slotted screws in each cover. Set the lug covers aside. Loosen the wire binding screws at all three connections and remove all wires from the lugs, making sure the wires are properly labeled for reinstallation.

3. Close the circuit breaker by moving handle to the ON position to perform inspection of hidden internal components.

NOTE: Steps 4 through 6 apply only to Breakers that are UL Listed only (appropriately labeled on trip unit cover). Because of differences in product construction, steps 4-6 do not apply to circuit breakers having ONLY IEC Certification.

4. Insert the probe tool into hole in lug shroud on the line side of the circuit breaker, through a small hole at the center of the gold-colored perforated metal grid, and through internal parts of the circuit breaker as shown in Illustration 2. The probe should enter the internal parts at approximately 25 degree angle from the front face of the circuit breaker (see Illustration 3). There should be very little resistance to insertion, with the probe dragging slightly on the internal parts. Use the template (Illustration 7) on the last page of this instruction to ensure proper angle orientation.

Illustration 2 Insert Probe at 25 Deg. Angle

5. If the fiber is present, the probe will bottom out at the first indicator (see Illustration 4) when the handle of the probe is angled inch either side of the centerline of the pole

Illustration 4 - Probe First Indicator

If the fiber is missing, replace the circuit breaker.

6a. To determine if fiber is correctly oriented: Center the probe along the centerline of the pole, and insert the probe further. The probe must be able to advance when aligned with the centerline of the pole so that the first indicator on the probe passes the edge of the shroud hole (Illustration 5). There will be a small amount of side-to-side play (about 1/8 inch), but much less than when the probe was inserted to the first mark as in the above inspection. Do not advance the first indicator of the probe past the perforated metal grid or the probe may become jammed.

Illustration 5 - Checking Fiber Orientation - First Probe Indicator Passed Shroud Hole

6b. If the fiber is incorrectly oriented, the probe will bottom out at the first mark when the probe is centered on the centerline of the pole. If fiber is incorrectly oriented, disable the breaker, until it is replaced.

Illustration 6 - Missing and Incorrectly Positioned Fiber (Left pole fiber is missing, center pole is correct, Right pole is incorreclty positioned)

NOTE: Do not remove cover to check for fibers and arc stacks. Illustration 6 shows cover removed for Illustration purposes only.

7. Pull the probe straight back so that the first indicator is - 1 inch from the hole edge. Move the probe to the left or right edge of the shroud hole. Insert the probe until it bottoms out.

8. If the arc stack is present the probe will bottom out just before the first indicator reaches the shroud hole edge when the probe handle is inch from the center of the pole axis. If the arc stack is not present, the probe will bottom out when the first indicator passes the lug shroud.

9. To further confirm a missing arc stack, push on the metal grid with a screwdriver, (the grid that the probe has been inserted through for previous tests). If the grid falls forward, the arc stack is missing.

10. If an arc stack is not present, disable the circuit breaker, until it is replaced.

11. If arc stacks are present and the fiber, on UL listed circuit breakers, is present and properly oriented, the circuit breaker can be reconnected, properly torqued and returned to service. Reinstall lug covers that were previously removed prior to inspection before energizing circuit breaker.

Illustration 7 - Template for 25 degrees