PRODUCT SUPPORT PROGRAM FOR REWORKING THE GROUND FAULT PROTECTION ON CERTAIN PM1360 POWER MODULES Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE GROUND FAULT PROTECTION ON CERTAIN PM1360 POWER MODULES

Usage:

TEBE1789-00

08Aug2014


D-418

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE GROUND FAULT PROTECTION ON CERTAIN PM1360 POWER MODULES

1404 1408 4459 770T
PS44441
NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS44441" 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.

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.


TERMINATION DATE

31Aug2015

PROBLEM

The existing earth fault protection system can cause nuisance trips on certain PM1360 Power Modules. If changes to the existing system is not addressed the power module will remain inoperable.

AFFECTED PRODUCT

Model Identification Number
3512B  YAY00840, 847, 853, 856, 858-860, 863-864, 879, 882, 892, 903, 1030-1033, 1107-1108, 1121

PARTS NEEDED

Qty

Part Number Description
1 3018317 TERMINAL-BLOCK
1 3018318 COVER-END
1 CABLE 2 WIRE
1 CT SOLID CT W120
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

Replace the flex CT with a solid CT and the removal of the RCC420 signal converter.

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

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
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%
 NOTE: This is a 2.0-hour job



PARTS DISPOSITION

Hold the Flex CT and the RCC Module for 30 days for a possible Parts Return Request (PRR). Contact Alan Daniel at Daniea@cat.com or Jo Liang at Liang_Jo@cat.com for a Parts Return Request (PRR) to be issued to you through the Send-It-Back process. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
 
 
 


Rework Procedure


 
Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing the rework.

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.

Remove the flex CT from around the load cables. Image1.1.1
Image1.1.1
 
Disconnect all the wires from the RCC 420 signal converter located in the upper controls box. Insulate wire ends and stow. Remove the RCC 420. Image1.2.1

Retain the flex CT and the RCC 420 signal converter. Refer to the Parts Disposition section.
Image1.2.1
 
Install the new W120 CT
Fasten the CT to the tray beneath with hardware and if needed install extra cable ties around the load cables to the CT.

Parts Needed

1 Solid W120 CT
Image1.3.1
 
Route the two wire cable from the CT to the RCM 420 relay. Strip the black cable insulation to expose wires. Strip each individual wire and install ferrules on each wire end. Image1.4.1. Trim back shield wire to edge of black insulation. Install wire ends into the CT terminals as shown in Image1.4.2 (do not connect shield wire)

Parts Needed
1 2 Wire Cable (Black)
Image1.4.1
Image1.4.2
 
Refer to Image 1.5.1
Install an earth terminal block 3018317 and an end cover 3018318 to the DIN rail to the right of the RCM 420 relay 1). At the end of the cable routed to the RCM 420 strip cable insulation back to expose the individual wires. Add insulation tape or tube to the shield wire. Strip each of the remaining wires and attach ferrules to all wire ends. Remove the two wires located at the top of the RCM 420 2). Install the new wires from the cable into the terminals the wires were removed from. Install the shield wire to the earth terminal block 3).
Image1.5.1
 
Adjust Settings and Test

1) The alarm/trip point on the relay can be configured as required. For test purposes configure to 300mA which will allow the unit to be externally tested.

2) Run the generator set. Install test socket into the receptacle. Using RCD tester apply 300mA and holding the orange test button as shown in Image1.6.1. Once applied the generator breaker will trip and the genset will shut down displaying an earth leakage fault on the ComAp controller display. Reset the fault.

3) Return the alarm trip point on the relay back to the required configuration. The power module can be returned to service.
Image1.6.1
 
 

Caterpillar Information System:

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