PRODUCT SUPPORT PROGRAM FOR REWORKING THE BATTERY CHARGER HARNESS ON CERTAIN C4.4 AND C6.6 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE BATTERY CHARGER HARNESS ON CERTAIN C4.4 AND C6.6 GENERATOR SETS

Usage:

REBE7381-00

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04Aug2011

U-320

A-266

D-286

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE BATTERY CHARGER HARNESS ON CERTAIN C4.4 AND C6.6 GENERATOR SETS
1406 1401 1408		PS52063

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52063" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31Aug2013

PROBLEM

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The existing battery charger on certain C4.4 and C6.6 Generator Sets can fail to charge the generator set battery. This is due to the high internal resistance of the battery charger harness. The fault is with the battery charger harness and not the battery charger.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	D4B01439, 1476-1477, 1490, 1494, 1496-1499, 1602-1603, 1605-1607, 1609-1614, 1616-1626, 1628-1630, 1632, 1634, 1636-1638, 1643, 1649-1653, 1655-1656, 1658, 1661-1666, 1672, 1674-1675, 1677-1682, 1686, 1688-1691, 1695, 1697-1699, 1701, 1703-1708, 1710-1712, 1714-1716, 1720-1722, 1731, 1733-1744, 1746-1777, 1779-1780, 1782-1783, 1785-1791, 1793-1796, 1800-1809, 1813-1818, 1826-1828, 1831, 1833-1838, 1840-1865, 1868, 1871, 1874-1875, 1877-1879, 1882-1891, 1893-1907, 1909-1915, 1920-1925, 1927-1930, 1932-1935, 1937-1956, 1958-1961, 1963-1966, 1993-1994, 1996, 2000-2001, 2003-2004, 2012-2013, 2018-2019, 2021 GLD00432, 444, 453, 456, 459, 461-463, 465, 471-473, 475, 477, 480, 484-490, 497-498, 500-503, 506-508, 512, 514-518, 522-525, 527-533, 535, 540-541, 543, 546-549, 552, 559, 561-565, 574-577, 590-603, 608-611, 613-624, 626-636, 639-651, 656-659, 664-669, 671-692, 694, 696-700, 703-706, 708-714, 716-720, 722-723, 725, 727-731, 733
C6.6	N6D01522, 1555, 1563, 1568, 1572, 1578-1579, 1581-1590, 1595-1597, 1600-1606, 1609-1615, 1619-1624, 1628-1629, 1633, 1635-1641, 1643-1646, 1649-1650, 1652-1654, 1657-1658, 1663-1668, 1671-1706, 1710, 1714-1716, 1720-1721, 1723-1749, 1751-1752, 1754-1755, 1757-1758, 1760, 1764-1766, 1768-1769, 1771, 1773-1777, 1781-1786, 1789, 1792, 1795-1799, 1801-1803, 1806-1810, 1815-1818, 1820, 1822-1824, 1830-1831, 1834, 1837-1838, 1841-1845, 1847-1881, 1883-1891, 1893, 1896, 1899-1905, 1907-1910, 1912-1914, 1916-1917, 1920, 1925-1927, 1929-1930, 1932-1941, 1943-1948, 1950-1960, 1964-1985, 1987-2000, 2002-2005, 2007-2009, 2012-2017, 2020

PARTS NEEDED

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Qty	Part Number	Description
1	3704169	HARNESS AS (EXT BAT CH)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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If the existing battery charger fails to charge the generator set battery, the fault can be corrected by replacing the existing battery charger harness with a new improved design, which has a lower internal resistance. Details of the action required can be found in 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, 0-24 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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1. Locate and turn off A/C voltage supply breaker to the Generator set battery charger. Remove the battery negative cable and apply lock out and tag out policy.

3. Remove the battery charger cover (1) by unscrewing the four screws (2) illustrated in Image1.2.1.

Image1.2.1

4. Disconnect the A/C input (1) and D/C output (2) wires from the terminals and the earth (3) from the grounding connector as illustrated in Image1.3.1 and Image1.3.2.

Image1.3.1

Image1.3.2

5. Remove the harness from the charger by loosening the lock nut on the gland as illustrated in Image1.4.1.

Image1.4.1

6. In the control panel, remove the trunking covers (1) as illustrated in Image1.5.1. Disconnect the battery charger circuit (2), wire number's +, 5, 131, 131 and ETH.

Image1.5.1

7. Remove the harness from the control panel, by loosening the lock nut on the gland (1) as per Image1.6.1.

Image1.6.1

8. To fit the new 370-4169 Harness, secure the gland with wire numbers 131, 132 & ETH exiting from it, as illustrated in Image1.7.1. Route the wires through the trunking along the path indicated in Image1.7.2 to the battery charger terminals (2). Terminate ETH (1) in the earth terminal, 131 in the neutral terminal (2) and 132 in the live terminal (3) as illustrated in Image1.7.3. Replace the trunking in the control panel as per Image1.7.4

Image1.7.1

Image1.7.2

Image1.7.3

Image1.7.4

9. Route the harness containing wires 131, 132, '+' and 5, along the original path to the battery charger, securing with cable ties where required (1) as illustrated in Image1.8.1.

Image1.8.1

10. Fit the gland (1) to the body of the battery charger as illustrated in Image 1.9.1 and secure using the locking nut (2) as per Image1.9.2. Route the wires throught strain relief (3) as per Image1.9.3. Terminate wires as follows, 132 to L (4), 131 to N (5), + to + (6) and 5 to - (7). Terminate the ETH to the grounding connector (8) as per Image1.9.4.

Image1.9.1

Image1.9.2

Image1.9.3

Image1.9.4

11. Route the remaining part of the harness along the side of the generator (1) to the starter motor (2) as illustrated in Image1.10.1.

Image1.10.1

12. Terminate + wire on the positive terminal (1) and the number 5 wire on the negative terminal (2) of the starter motor as per Image1.11.1.

Image1.11.1

13. Replace the cover (1) on the battery charger and secure with 4 of screws (2) removed in Step 2.

Image1.12.1

14. Reconnect the auxiliary power supply for battery charger and heaters, and reconnect battery cables. Check for correct operation of the battery charger.