PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CABLE TRAY ON CERTAIN PM3516B POWER MODULES Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CABLE TRAY ON CERTAIN PM3516B POWER MODULES

Usage:

TEBE0336-01

15Oct2013
(Revised 21Feb2014)


A-350
D-419

 

Safety

  
  

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CABLE TRAY ON CERTAIN PM3516B POWER MODULES

4459
PI10945
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10945" 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 "PI10945" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

 
NOTE:

This Revised Service Letter replaces the 15Oct2013 Service Letter. Changes have been made to the Parts Needed and Rework Procedure.



PROBLEM

The cable tray needs to be reworked on certain PM3516B Power Modules. The existing cover mounting bolts can abrade the load cables resulting in failure and may in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

Model Identification Number
PM3516  NBR00100-00121, 128-137, 142-213, 360-361
PM3516B  BPD01273-01282

PARTS NEEDED

Qty

Part Number Description
2 3L7634 TERMINAL-RING (AS REQUIRED)
4 1428194 RIVET-BLIND
300 3146905 CABLE-BULK (AS REQUIRED)
1 STRUT CHANNEL (SEE ACTION REQUIRED)
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

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 load cables. The procedure details the installation of a strut channel for certain PM3516 generator sets with a 282-2600 Cable Duct Group. The channel is to prevent the load cable from contact with the cable tray cover mounting bolts (see Image 1 below). This procedure includes verification that no insulation damage exists on the load cables requiring replacement.

The strut channel is obtained locally by the dealer in the material and dimensions as specified in the Rework Procedure.

Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework.
Image1

OWNER NOTIFICATION

Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%
 NOTE: This is a 2.0-hour job
A maximum of $30.00 U.S. is allowed for the strut channel.

If necessary, an additional 1 hour is allowed for cable replacement.


PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
 
 
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
 
 
 
EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE CABLE TRAY ON CERTAIN PM3516B POWER MODULES

MODELS INVOLVED - PM3516B

Dear Cat Product Owner:


The cable tray needs to be reworked on the products listed below. The existing speed nuts can abrade the load cable resulting in failure and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

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

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 15Oct2013 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 15Oct2013 Service Letter


Rework Procedure


 
Identify the correct enclosure in the personnel access room. Start by removing the 10 bolts securing the right cover. Remove the cover and store for reuse. Remove eight bolts to the left cover. Remove the cover and store for reuse.
Image1.1.1
 
Once the covers are removed inspect the cables for damage to the insulation in locations where the cable has come in contact with a bolt. If the insulation is pierced or shows signs of abrasion, the 314-6905 Cable will need to be replaced along with two 3L-7634 Ring Terminals. Minor indentation of the insulation shown in Image1.2.1 is acceptable once the cable has been meggered as a final check.

Parts Required:
2 3L-7634 Ring Terminals (As Required)
300cm 314-6905 Cable (As Required)
Image1.2.1
 
Procure 1 meter of galvanized or zinc plated strut channel in any of the 4 options shown in Image 1.3.1. Drill 20mm holes or cut 5cm L shaped sections off each end for clearance from the bolt heads shown in Image 1.3.3 upon installation of the channel.

CAUTION: Ensure that no burrs are present after cutting and that all sharp edges are ground smooth.

Parts Required:
1 Strut Channel (100cm)
Image1.3.1
Image1.3.2
Image1.3.3
 
Lift and move the cables to the rear of the tray to make space for installing the strut channel. Image shows this being done with rope.
Image1.4.1
 
Place the channel against the the inside wall of the cable tray. Ensure that the channel lies flush with the bottom of the tray. Starting at 100 mm from the either end of the cable tray drill a 3/16" (4.8 mm) pilot hole through the bottom of the tray and through the center of the strut channel. Remove any burrs that may remain. With a rivet gun install a rivet attaching the channel to the tray. Repeat these steps installing 3 additional rivets evenly spaced along the length of the tray.

Parts Required:
4 Rivet 142-8914
Image1.5.1
 
Finish by reinstalling both covers of the cable box securely tightening all bolts to 6 +/- 1 NM.
Image1.6.1
 
 

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