PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE INSTRUMENT HARNESS ON CERTAIN C6.6 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE INSTRUMENT HARNESS ON CERTAIN C6.6 GENERATOR SETS

Usage:

TEBE0967-01

Show/hide table

30Sep2014

(Revised 28Oct2014)

U-563

A-421

D-507

O-482

TM-24

Show/hide table

*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE INSTRUMENT HARNESS ON CERTAIN C6.6 GENERATOR SETS
1408 4490 7451		PI10989

Show/hide table

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 as soon as possible. When reporting the repair, use "PI10989" 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 "PI10989" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table


NOTE:	This Revised Service Letter replaces the 30Sep2014 Service Letter. A change has been made to the Mail Codes.

Show/hide table

PROBLEM

Show/hide table

The control panel power supply cable is connected at the wrong location on certain C6.6 Generator Sets. The existing harness may fail if overloaded which may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

Show/hide table

Model

Identification Number

C6.6

C6T00101-00104, 155-158, 160-167, 169-221, 223-231, 233-237, 239-240, 242, 244-256, 258-404, 406-413, 416-419, 421-473, 475-481, 483-518, 520-535, 537-555, 557-563, 565, 567-586, 589-603, 605-606, 608-615, 617, 619-621, 623-666, 669-696, 698, 700-701, 703-722, 724-728, 731-738, 740-747, 749-751, 753-773, 775-776, 778-782, 784-797, 799-807, 810-811, 814-828, 830-836, 838-860, 862-867, 870-873, 875-888, 890-891, 893, 895-901, 903-911, 913-918, 920-927, 931-943, 946-950, 952, 956, 958-960, 962-973, 976-989, 991, 993-1002, 1004-1005, 1008, 1010-1022, 1024, 1026

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	4518348	Glow Plug Relay Harness Modification Assembly
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

Show/hide table

Rework the the existing instrument wire harness using a 451-8348 Glow Plug Relay Harness Assembly to protect the instrumentation in case of a fault or circuit overload. The harness assembly services both 12 and 24 volt circuits.

The instrumentation 12 or 24 Volt power is currently connected to the incoming side of the glow plug circuit breaker. This means the circuit has unprotected battery power. If there is a circuit fault, battery power can be drawn through the small supply cables and if overloaded could burn the cables. This retrofit fit wiring kit ensures the instrumentation and associated wiring is protected by the 20 amp circuit breaker.

Refer to the attached Rework Procedure.

Show/hide table

OWNER NOTIFICATION

Show/hide table

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

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

Show/hide table

NOTE: This is a 1.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

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

Show/hide table

COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE INSTRUMENT HARNESS ON CERTAIN C6.6 GENERATOR SETS

MODELS INVOLVED - C6.6

Dear Cat Product Owner:

The instrument wire harness needs to be inspected and reworked on the products listed below. The existing instrument wire harness has unprotected battery power, should a fault or overload take place, the small cables could burn. This may in conjunction with other factors or circumstances, result in a risk of personal injury or death. This rework will ensure the cables are protected. 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 30Sep2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 30Sep2014 Service Letter

Rework Procedure

Show/hide table

WARNING:
Ensure that all lockout/tagout procedures for the site are followed. Read and understand the Safety Section in the Operation and Maintenance Manual. Ensure the area is safe and free from unwarranted potential hazards. Isolate the battery and mains voltage before starting work.

Image 1.2.1: 3 way spliced cable 451-8348 Glow Plug Relay Harness Modification Assembly.
-

Image1.2.1

Image 1.3.1: Parts to be removed [3 cables]
-

Image1.3.1

The following steps describe how best to remove the 3 cables. The fitting of the kit (spliced cable) is simply a reverse of the instruction for removal, with the exception of all three being connected through the new spliced cable 451-8348 Glow Plug Relay Harness Modification Assembly to the secondary side of the 20 AMP Circuit Breaker.

Step 1: Image 1.5.1 Remove the cover plate on the relay bracket [4bolts]
-

Image1.5.1

Step 2: Image 1.6.1; Remove the screws that support the 20 AMP Circuit Breaker.
-

Image1.6.1

Step 3: Image 1.7.1; Remove and retain for refitting, the glow-plug intermediate relay.
-

Image1.7.1

Step 4: Image 1.8.1; Remove the feed wire from 20 amp circuit breaker to the relay base. Use a small straight blade screwdriver to release the connector.
-

Image1.8.1

Step 5: Image 1.9.1; Remove the ECM supply cable and connector.
-

Image1.9.1

Step 6: Image 1.10.1; Remove the supply cable from the glow-plug circuit breaker to the instrument supply 4 PIN Deutsch plug.
-

Image1.10.1

Step 7: Image 1.11.1; Fit the new 3 way (eye terminal) spliced cable to the 20 AMP circuit breaker.
-

Image1.11.1

Step 8: Image 1.12.1; Refit and secure the 20 AMP circuit breaker with the 2 screws.
-

Image1.12.1

Step 9; Connect new splice into relay base and refit the glow-plug relay.

Step 10; Reconnect the ECM supply, Reconnect the new splice to the Deutsch connector.

Step 11; Check your work before refitting the relay cover with [4 bolts]

Step 14; Reconnect battery and mains voltage (check work) and test.
-

Before and After Wire Diagram. Image 1.14.1
-