PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CRIMP OF CABLE LUGS ON CERTAIN 3516E GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CRIMP OF CABLE LUGS ON CERTAIN 3516E GENERATOR SETS

Usage:

TEBE9124-00

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16May2019

O-254

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING THE CRIMP OF CABLE LUGS ON CERTAIN 3516E GENERATOR SETS
1405 4459		PI33023

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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 "PI33023" 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 "PI33023" 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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COMPLETION DATE	TERMINATION DATE
30Nov2019	31May2020

PROBLEM

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The lugs on all generator cables may not be properly crimped on certain 3516E Generator Sets. If one or more lugs may not be properly crimped it may lead to a generator failure.

AFFECTED PRODUCT

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Model	Identification Number
3516E	JH800103, 110-112, 114-115, 120-123
3516E HD	LCK00101-00102, 109-111

PARTS NEEDED

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Qty	Part Number	Description
12	LUG	TERMINAL LUG (If/As Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 41% 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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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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is being performed. Follow the proper lock out tag out procedures to protect against unintended operation, unexpected movement, 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 and local and remote controls before you perform any service to the machine.

Action Required

1. Isolate the generator set from starting, and open all up and downstream disconnects.

2. Inspect lugs on all power cables for crimping evidence. There should be an indentation on each lug like Image 1, indicating the lug has been crimped with a high pressure crimping tool.

3. If the cable is suspected to be not crimped correctly, do not start the Generator Set.

4. Have the Dealer Technical Communicator (TC) submit a request to CPI number 443097 through CPI Feedback within the Service Information Management System (SIMSi).
Document and include the following:
Photos of suspect lug(s)
Generator Set Serial Number
ESO
Attach Product Status Report

5. Replace cable lug(s) if/as necessary if not crimped correctly.

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Image1

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
An additional 2 hours is allowed for each cable lug that is reworked.

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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 INSPECTING THE CRIMP OF CABLE LUGS

MODELS INVOLVED - CERTAIN 3516E GENERATOR SETS

Dear Cat Product Owner:

The generator cables need to be inspected on the products listed below. The existing cables may have one or more cable lugs which have not been crimped correctly. All cables need to be inspected for verification of correct lug crimping. 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 16May2019 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 16May2019 Service Letter