PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE ELECTRICAL GROUNDING CABLES ON CERTAIN C4.4 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE ELECTRICAL GROUNDING CABLES ON CERTAIN C4.4 GENERATOR SETS

Usage:

TEBE4591-01

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25Jul2016

(Revised 19Oct2016)

U-385

A-292

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE ELECTRICAL GROUNDING CABLES ON CERTAIN C4.4 GENERATOR SETS
4459 7274 7405 1408		PI32663

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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 "PI32663" 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 "PI32663" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 25Jul2016 Service Letter. Changes have been made to the Parts Needed, and Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31Jan2017	31Jul2017

PROBLEM

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The electrical grounding cables need to be rerouted on certain C4.4 Generator Sets. The existing electrical grounding cables can be obstructed by a foam seal that was placed along the base of the enclosure to prevent water ingress.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	MZT00101-00106, 108-210

PARTS NEEDED

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Qty	Part Number	Description
2	8T4121	WASHER-HARD
1	8T4195	BOLT-HEX HEAD
1	2284798	FILM-GROUND
1	3445675	NUT-HEX
1	4336710	CABLE AS
1	CORROSION_INHIBITOR	CP8-TB Kopr-Shield Anti-Corrosion Compound 8oz
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

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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

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NOTE: This is a 1.0-hour job

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PARTS DISPOSITION

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

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE ELECTRICAL GROUNDING CABLES

MODELS INVOLVED - CERTAIN C4.4 GENERATOR SETS

Dear Cat Product Owner:

The electrical grounding cables need to be rerouted on the products listed below. The existing electrical grounding cables can be obstructed by a foam seal that was placed along the base of the enclosure to prevent water ingress. 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. Please refer the dealer to their Service Letter dated 25Jul2016 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 25Jul2016 Service Letter

Rework Procedure

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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 generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. 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.

This package is currently assembled with the foam seal in between the package enclosure and the base (reference Images 1.2.1 and 1.2.2). In order to improve the ground connection, the following changes need to be made.

Images 1.2.1 and 1.2.2 are for reference purposes only.

Image1.2.1

Image1.2.2

Rework Procedure

1. Images 1.3.1 and 1.3.2 show a generator set that needs to be reworked. Open the control panel door, so that the breaker panel is visible.

Image1.3.1

Image1.3.2

2. Remove the breaker panel fasteners so that you can gain access to the breaker cabling.

3. Remove the ground cables from the existing ground point. This grounding point will be referenced as the original grounding point for the remainder of this document (reference 1.4.1).

Image1.4.1

4. Remove the access panel as shown in Image 1.5.1. In order to remove this panel you will first need to remove the genset base access panel so that you can gain access underneath the genset (reference Image 1.5.2). Once this panel is removed, you will have better access to remove the cable access panel. This panel is attached by rivets and is best removed by drilling out the rivets.

Image1.5.1

Image1.5.2

5. Once the panel is removed reroute the ground cables by pushing them through the cable access opening (referenced in Image 1.6.1).

Image1.6.1

5. Once the ground cables are routed underneath the genset create a new ground point. This ground point will serve as the connection hub for all the grounding cables (including the cable assembly listed in the Parts Needed section of this service letter).

6. Drill 11.5 mm (+/- 0.5 mm) hole in the base rail (reference Image 1.8.1 & 1.8.2).

Image1.8.1

Image1.8.2

7. Remove the paint surrounding the hole by either grinding or sanding the paint off on the inside of the base rail underneath the genset. Once completed cover it with corrosive inhibitor (as shown in Image 1.9.1 and referenced in the Parts Needed section of this service letter).

Also use the grounding film to reference the new grounding point. An example of how the grounding film should look is shown in Image 1.9.2.

Image1.9.1

Image1.9.2

8. Attach the ground cables to the new grounding point, please include the additional cable assembly (referenced in the Parts Needed section of this service letter).

Use Image 1.10.1 to reference this step.

Image1.10.1

9. The other end of the cable assembly will go back inside the breaker panel by going through the cable access opening. Now attach this cable assembly to the original grounding point so as to tie in the metal enclosure. This procedure must be done because the foam between the enclosure and the base is still present (reference Images 1.2.1 and 1.2.2).

11. Replace the access panels for the genset base and the breaker to complete the service letter.