PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING THE COPPER 356-9861 BUSBAR SUPPORT BRACKET ON 166-2720 GENERATORS FITTED TO CONTAINERISED 3516B GENSETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING THE COPPER 356-9861 BUSBAR SUPPORT BRACKET ON 166-2720 GENERATORS FITTED TO CONTAINERISED 3516B GENSETS

Usage:

REBE5735-00

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06Jan2010

O-10

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING THE COPPER 356-9861 BUSBAR SUPPORT BRACKET ON 166-2720 GENERATORS FITTED TO CONTAINERISED 3516B GENSETS
4460 4459		PI10788

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10788" 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 "PI10788" 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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PROBLEM

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Under extreme loading conditions the 356-9861 Busbar Support Brackets have exhibited buckling that may lead to electrical short circuit conditions that could result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
3516B	FDX00521-00528, 539, 541-543, 546-548, 551-552, 554-568

PARTS NEEDED

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Qty	Part Number	Description
1	3569862	BRACKET (Direct Shipped to Dealers)
NOTE: The 356-9862 Brackets have been directly shipped to the affected dealers due to the circumstances of this program. Parts will not need to be ordered.

ACTION REQUIRED

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Replace the 356-9861 Busbar Support Bracket fitted inside the terminal box of the 166-2720 Generator with a new 356-9862 Bracket.

NOTE: This only applies to generators fitted to 3516B Containerised Gensets.

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 1.5-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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND REPLACING THE COPPER 356-9681 BUSBAR SUPPORT BRACKET ON 166-2720 GENERATORS

MODELS INVOLVED - 3516B Containerised Gensets

Dear Caterpillar Product Owner:

The 356-9861 Busbar Support Bracket fitted inside the terminal box of the 166-2720 Generator needs to be replaced. This only applies to generators fitted to 3516B containerised gensets. Under extreme loading conditions the brackets have exhibited buckling that may lead to electrical short circuit conditions that could result in personal injury or death. You will not be charged for the service performed.

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 06Jan2010 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 06Jan2010 Service Letter

Rework Procedure

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1. Isolate Genset before commencing any work on the unit; open Genset breaker, activate Emergency Stop, disconnect the auxiliary power supply for battery charger and heaters, and disconnect battery cables. Ensure health and safety 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. Remove the side covers from the generator terminal box to gain access to the copper busbars and the support bracket. Image1.2.1.

3. Provide adequate support for the copper busbars and cables.

NOTE: The weight of the copper busbars and the cables needs to be supported before the support bracket can be replaced. Total weight is approximately 120 Kg.

4. Cable tie the bottom insulator bars to the top insulator bars to prevent the spacers from falling once the copper support bracket is removed.

Image1.2.1

5. After the weight has been supported, loosen the four nuts on the underside of the support bracket that secure the threaded rod which clamps the isolator bars together Image1.3.1

6. Remove, and retain for reuse, the screws, nuts, and washers securing the support bracket to the front of the Generator framework. Once the screws, nuts, and washers have been removed, the support bracket should be free to be removed. Image1.3.1

NOTE: Make sure the support bracket is being held when the nuts and screws are being removed.

Image1.3.1

7. Install the new 356-9862 Support Bracket by lining up the threaded rod with the slotted holes in the top of the support bracket. Use the existing nuts and washers to secure the threaded rod to the support bracket. Hand tighten only.

NOTE: The threaded rods and insulator bars will need to be moved closer to the front of the generator due to the re-positioning of the slots on the support bracket.

8. Once the isolator bars have been secured, use the original screws, nuts, and washers retained from Step 6 to secure the new support bracket to the generator frame. Hand tighten only.

9. Fully tighten all fasteners once the new support bracket has been fully assembled.

10. Ensure structure is secure.

11. Remove the cable ties holding the insulator bars together.

12. Remove the temporary supports supporting the weight of the copper busbars and cables during the change.

13. Reinstall the generator extension covers.

14. Clear generator area, reconnect batteries, and release emergency
stop.

15. Run functional test on Genset.