PRODUCT SUPPORT PROGRAM FOR INSTALLING UL BATTERY CHARGERS ON CERTAIN C4.4 POWERED RENTAL GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING UL BATTERY CHARGERS ON CERTAIN C4.4 POWERED RENTAL GENSETS

Usage:

REBE5799-00

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01Feb2010

U-40

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING UL BATTERY CHARGERS ON CERTAIN C4.4 POWERED RENTAL GENSETS
1406 1401		PS43030

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43030" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

28Feb2011

PROBLEM

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The battery charger group was inadvertently omitted from production.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	D4D00611, 664-665, 667-668, 670, 673, 677-683, 685-689, 692-698, 700-703, 706-707, 710, 712, 716-720, 725-729, 732-733, 767-769

PARTS NEEDED

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Qty	Part Number	Description
4	5C9553	BOLT-HEX HEAD
4	9X8256	WASHER
1	2669668	CHARGER-BATTERY
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 14% 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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The UL battery charger needs to be installed on certain C4.4 Rental Generator Sets.

Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-1000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
1001-2000 hrs, 13-24 mo	100.0%	100.0%	0.0%	0.0%	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.

Rework Procedure

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Refer to Parts Manual, SEBP5267-01, 270-6794 Mounting Group - Battery Charger and 309-3752 Wiring Group - Generator for additional information.

1. Isolate the genset before commencing any work on the unit, open the genset breaker, activate the emergency stop, disconnect the auxiliary power supply for the battery charger and heaters, and disconnect the 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. Mount the 266-9668 Battery Charger to the rear of the control panel using (Qty 4) 5C-9533 Bolts and (Qty 4) 9X-8256 Washers.

3. Remove the two screws (1) from the bottom panel of the battery charger to gain access to the terminals. Image1.1.1.

Image1.1.1

4. Locate the section of the harness (1) indicated in Image 1.2.1. Remove the lock nut from the gland and feed the wires through the gland hole (2) on the side of the battery charger illustrated in Image 1.2.2. Refit the lock nut, and secure the gland to the charger.

Image1.2.1

Image1.2.2

5. Terminate the harness wiring as illustrated in Image1.3.1

6. Refit the lower plate and two screws removed in Step 3.

7. Reconnect any auxiliary supplies and battery cables. Check for correct operation of the battery charger.