PRODUCT SUPPORT PROGRAM FOR MODIFYING THE DOOR LATCH MECHANISM ON CERTAIN C2.2, C4.4, AND C6.6 RENTAL GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR MODIFYING THE DOOR LATCH MECHANISM ON CERTAIN C2.2, C4.4, AND C6.6 RENTAL GENERATOR SETS

Usage:

REBE7274-00

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07Jul2011

U-272

A-224

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR MODIFYING THE DOOR LATCH MECHANISM ON CERTAIN C2.2, C4.4, AND C6.6 RENTAL GENERATOR SETS
7274 7273		PS43318

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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 "PS43318" 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

31Jul2012

PROBLEM

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The existing door latch mechanism utilized in the 263-0761 Lock assembly does not fully engage the door striker and allows the door to open.

AFFECTED PRODUCT

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Model	Identification Number
C2.2	GBE00108-00168, 171-174, 181-183, 186, 191, 206-208, 210-212, 214-219, 221-225, 230, 235-236, 238, 240, 243, 252-254, 269, 277, 284-286, 290-293, 304, 312-314, 350-360, 383, 401-412, 414-419, 423-433, 435-439, 442, 445, 462-464, 469-471, 473, 476, 478-479, 481-486, 489-492, 502-503, 507, 509, 511, 514-519, 522-528, 531-533, 535, 537, 542-543, 558-559, 562-563, 570-571, 574, 577-579, 583-585, 587-595, 597-600, 603, 608-609, 613, 618, 630-634, 639-641, 643-646, 650-654, 660-661, 667-668, 674, 676-677, 684, 687-689, 691-693, 696-701, 703-704, 707-708, 712, 714, 720-721, 726-738, 740-741, 743-744, 748-749, 751-752, 757, 762, 766, 770, 772, 775-777, 780-782, 784, 791-792, 795, 797-799
C4.4	D4D00734-00763, 772-943, 946-969, 971-1000, 1944-1945, 2046-2054 GLE00301-00302, 700-756, 758-764, 766-902, 904-929, 1000-1049
C6.6	MRW00100-00102, 104-327

PARTS NEEDED

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Qty	Part Number	Description
16	3115307	SCREW
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 26% 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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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%
0-5000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	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.

Rework Procedure

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Step 1 - Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect all shore power connections and disconnect battery cables.

Ensure all 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.

Only qualified repair personnel should service this equipment.

Step 2 ? Locate and identify each 263-0761 Lock assembly on the generator set. Refer to Image1.2.1.

Image1.2.1

Step 3 ? Remove each 263-0761 Lock assembly from the applicable door panel. It is recommended that each lock assembly and door panel be distinctively marked to ensure that the lock assembly is installed in the correct door panel.

Step 4 ? Retain all mounting hardware for reuse.

Step 5 - Place the 263-0761 Lock assembly in a suitable clamping device such as a vice and firmly secure into place. The 263-0761 Lock assembly should be oriented with the latch mechanism face up. Refer to Image1.2.1.

Step 6 ? The latch mechanism modification will consist of two separate cut patterns for each side of the latch. For the first cut pattern, scribe both sides of the latch mechanism in accordance with the dimensions specified in Image1.4.1.

Image1.4.1

Step 7 ? Using a standard pneumatic high speed grinder equipped with a 0.25 inch diameter conical shaped grinding bit, remove the latch material as defined in Step 6.
Refer to Image1.5.1.

Image1.5.1

Step 8 - For the second cut pattern, scribe both sides of the latch mechanism in accordance with the dimensions specified in Image1.6.1.

Image1.6.1

Step 9 ? Using a standard pneumatic high speed grinder equipped with a 0.25 inch diameter conical shaped grinding bit, remove the latch material as defined in Step 8.

Step 10 - Using a suitable metal file, remove any rough edges along the cut line of the latch mechanism.

Step 11 ? Install the modified lock assembly into the original door panel as identified in Step 3.

Step 12 ? Locate the existing canopy retaining hardware in the canopy access door area.
There will be one bolt per corner. Refer to Image1.8.1.

Image1.8.1

Step 13 ? Identify the type of retaining hardware utilized. The hardware will be either a Hex Head bolt or a Button Head bolt. Refer to Image1.9.1.

Image1.9.1

Step 14 ? If the generator set is equipped with Hex Head retaining hardware, remove the Hex head bolts and replace the Hex head bolts with 311-5307 Screws. Tighten the 311-5307 Screws securely to the canopy door area.

Step 15 ? Confirm that each door panel closes properly and the lock assembly provides a positive latching action. Adjust alignment of the lock assembly as required. The latching mechanism is to fully engage the striker bar.