PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE BRAIDED POWER CABLES ON CERTAIN 3406C GENERATOR SETS SHIPPED FROM NEWBERRY Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE BRAIDED POWER CABLES ON CERTAIN 3406C GENERATOR SETS SHIPPED FROM NEWBERRY

Usage:

REBE5326-00

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03Sep2009

U-312

A-262

D-278

O-286

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE BRAIDED POWER CABLES ON CERTAIN 3406C GENERATOR SETS SHIPPED FROM NEWBERRY
4458 4460		PI31688

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31688" 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 "PI31688" 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:

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COMPLETION DATE	TERMINATION DATE
31Mar2010	30Sep2010

PROBLEM

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The protective mats and cable straps may not have been installed correctly around the braided power cables on certain 3406C generator sets shipped from Newberry, South Carolina. This may lead to wear and chafing on the power cables. The braided power cable installation system on these affected generator sets requires inspection and possible maintenance to address the possibility of wear and chafing.

AFFECTED PRODUCT

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Model	Identification Number
3406C	C2Y00005, 150-152, 155-442, 444-543, 545-749, 751-754, 757-1419, 1421-1472, 1474-1476, 1478-1482, 1487, 1490-1497, 1499-1508, 1535-1549

PARTS NEEDED

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Qty	Part Number	Description
16	7H8213	MAT-BAT BASE
38	7K1181	STRAP-CABLE
1	7X2639	TUBE-SHRINKABLE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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Install protective mats on braided power cables and bundle properly. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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 2.0-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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING GENERATOR SET BRAIDED POWER CABLES

MODELS INVOLVED - 3406C Generator sets

Dear Caterpillar Product Owner:

The protective mats and tie wraps may not have been installed correctly around the braided power cables on the products listed below. This may lead to wear and chafing on the cables. The braided power cable installation system on these affected generator sets requires inspection and possible maintenance.

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

Please refer the dealer to their Service Letter dated 03Sep2009 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 03Sep2009 Service Letter

Rework Procedure

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1. Isolate generator set before commencing any work on the unit; open generator set breaker, activate emergency Stop, disconnect the auxiliary power supply for battery charger and heaters and disconnect battery cables. Refer to Caterpillar maintenance manual for additional safety requirements; ensure the requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

2. Inspect the current braided power cables. If the insulation on the braided power cables has become damaged due to chafing and/or wear, fit a length of 7X-2639 Heat Shrinkable Tubing to cover the braided power cable affected area. The heat shrinkable tubing has an internal diameter of 50.8 mm (2 inches) before shrinkage and a minimum of 25.4 mm (1 inch) after shrinkage.

3. Apply hot air to the heat-shrink tubing to shrink it securely into place.

4. Add (4) 7K-8213 Rubber Mats to braided power cables as they enter the control panel as shown in image 1.2.1 to prevent wear and/or chafing from contact between braided power cables and the chassis. Ensure the mat protects the braided power cable entering or exiting the conduit by inserting approximately 1/2 of each mat inside of each conduit.

5. Secure the mats to the braided power cables with (8) 7K-1181 Cable Straps.

Image1.2.1

6. Add (4) 7H-8213 Rubber Mats to braided power cables as they enter the turret as shown in image 1.3.1 to better protect the braided power cables from chafing.

7. Secure the mats to the braided power cables with (8) 7K-1181 Cable Straps. Tighten the cable strap so the mats cannot slide or move along the braided power cable. Position the eye of the cable strap away from anything it may rub against.

Image1.3.1

8. Bundle all three phase braided power cables together inside the generator turret. This will prevent the braided power cables from sagging and coming into contact with objects inside the terminal box. Start with the middle phase, L2. Wrap one rubber mat around the braided power cable in the area where all three braided power cables will be bundled together but do NOT secure this rubber mat with the cable strap yet. Pull and position the other braided power cables, L1 and L3, under and above the L2 braided power cable, as shown in image 1.4.1. and image 1.4.2.

Image1.4.1

Image1.4.2

9. While holding all three braided power cables together, add (1) or (2) 7H-8213 Rubber Mats as required around the three phase braided power cables, as shown in image 1.5.1.

10. Secure all the mats with (2) 7K-1181 Cable Straps.

Image1.5.1

11. Add (1) 7H-8213 Rubber Mat around the neutral braided power cable where it meets the opening in the top of the alternator housing, as shown in Image 1.5.1.

12. Secure the mat with (2) 7K-1181 Cable Straps.

13. In some cases, the three braided power cables, L1, L2, and L3, cannot be bundled together. If that is the case, then bundle L1 and L2 together and bundle L3 and N together. After bundling, the braided power cables must form a stiff, rigid bundle and be protected from rubbing on the terminal box, sharp edges, and/or bus bars. The turret mats should then look similar to that shown in image 1.6.1.