PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE MAIN POWER DISCONNECT SWITCH ON CERTAIN C175 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE MAIN POWER DISCONNECT SWITCH ON CERTAIN C175 GENERATOR SETS

Usage:

REBE8443-01

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30Aug2012

(Revised 02Oct2012)

U-462

A-366

D-394

O-424

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE MAIN POWER DISCONNECT SWITCH ON CERTAIN C175 GENERATOR SETS
1411		PI10904

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10904" 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 "PI10904" 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:	This Revised Service Letter replaces the 30Aug2012 Service Letter. Changes have been made to the Parts Needed, Service Claim Allowances and Rework Procedure.

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PROBLEM

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The main power disconnect switch needs to be replaced on certain C175 Generator Sets. The existing main power disconnect switch can fail in the closed or open position allowing the main power to stay on while the main disconnect switch is in the off position or vice versa. This may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
C175-16	WYB00100-00112, 114-118, 124-129, 135-136, 138-454, 456-574, 576-677, 680, 682, 1000-1093

PARTS NEEDED

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Qty	Part Number	Description
1	3694098	SWITCH AS
1	4172752	CABLE AS
1	TERMINAL	3/8 INCH RING TERMINAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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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
Include outside expenses at cost for the ring terminal. Retain a copy of invoices for outside expenses for auditing purposes.

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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 REPLACING THE MAIN POWER DISCONNECT SWITCH ON CERTAIN C175 GENERATOR SETS

MODELS INVOLVED - C175-16

Dear Caterpillar Product Owner:

The main power disconnect switch needs to be replaced on certain C175 Generator Sets. The existing main power disconnect switch can fail in the closed or open position allowing the main power to stay on while the main disconnect switch is in the off position or vice versa. This may, in conjunction with other factors or circumstances, result in a risk of 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 30Aug2012 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 30Aug2012 Service Letter

Rework Procedure

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Warning - The following steps should be taken prior to performing this task so as to avoid personal injury:

1) Shut down the engine
2) Lock out and Tag out the Engine
3) Disconnect the battery
4) Isolate the generator set from all Loads and any other power sources.

Rework Procedure:

Step 1: Disconnect the 263-6535 Cable Assembly from the disconnect switch and ground stud. Refer to Image1.1.1. Also disconnect the customer supplied cable that goes from the battery to the disconnect switch.

Step 2: Remove the 161-7082 Disconnect Switch currently installed on the door of the power distribution box. Refer to Image1.1.2.

Image1.1.1

Image1.1.2

Step 3: Install the new 369-4098 Disconnect Switch. Refer to Image1.2.1.

Step 4: Install the new 417-2752 Cable Assembly. Ensure that the cable is secured to cable bundle with tie straps. Refer to Image1.2.2.

Step 5: Cut off the the 1/2 inch ring terminal and crimp on a 3/8 inch ring terminal on the customer supplied cable coming from the battery to the disconnect switch. Reconnect cable to disconnect switch.