PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE STATOR LEADS ON CERTAIN C27 GENERATOR SETS EQUIPPED WITH 1200 FRAME (SR5) AND 590 FRAME (SR4B) GENERATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE STATOR LEADS ON CERTAIN C27 GENERATOR SETS EQUIPPED WITH 1200 FRAME (SR5) AND 590 FRAME (SR4B) GENERATORS

Usage:

TEBE1485-00

Show/hide table

11Jun2014

U-334

A-242

Show/hide table

*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE STATOR LEADS ON CERTAIN C27 GENERATOR SETS EQUIPPED WITH 1200 FRAME (SR5) AND 590 FRAME (SR4B) GENERATORS
7274 4460		PI10971

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10971" 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 "PI10971" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

PROBLEM

Show/hide table

The stator leads needs to be inspected on certain C27 Generator Sets equipped with 1200 Frame (SR5) and 590 Frame (SR4B) Generators. There is a potential for stator cable chafing against the sharp edge of the generator control cabinet and eventually cause a short to frame failure, this failure in conjunction with other factors may result in a risk of personal injury or death.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
C27	GDS00101, 103, 105-106, 119, 134, 136, 138-140, 142-145, 148, 156-157, 160-162, 164-165, 170, 172, 174, 177-178, 181-182, 186, 225, 227, 235-244, 260, 270, 282, 290, 292, 294, 300, 309, 327-328, 332, 338-339, 350, 352-353, 355, 362, 366-367, 376, 378-379, 381-382, 384, 387, 390, 392, 453-454, 456, 458-461, 463, 467-471

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	CABLE_STRAP	WxL 12.5mm X 880mm QTY AS NEEDED, PROCURE LOCALLY
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

Show/hide table

Inspection Procedure

1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. 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 operation and disconnect/lockout all power sources before commencing any work.

2. Locate and remove cover shown on image 1.

3. Measure the clearance between the stator leads and the sharp edge of the generator control cabinet, the clearance should be at least 3/4" (19mm). For reference see image 2 or 3 depending on the frame you are working on.

4. Measure the clearance between the stator leads and the threaded inserts (rivet nuts) inside the panel, the clearance should be at least 3/8" (10mm) (please note: in most cases it would be desired to maintain the same distance of 3/4" (19mm) clearance between the leads and the threaded inserts (rivet nuts), however, if not possible as a minimum confirm that the clearance is at least 3/8" (10mm)). For reference see image 2 or 3 depending on the frame you are working on.

5. If the cables cannot be easily moved and there is a clearance of 3/4" (19mm) between the leads and the sharp edge of the rear control cabinet and 3/8" (10mm) between the leads and threaded inserts, and the cables are properly secured with tie straps no further action is required. Reinstall the cover and restore the unit to its operational condition.

6. If the cables are located, or can be moved within 3/4" (19mm) between the leads and the sharp edge of the rear control cabinet or 3/8" (10mm) between the leads and threaded inserts there is a potential for future stator cable chafing against the sharp edge of the generator control cabinet or threaded inserts and eventually cause a short to frame failure. Perform the Rework Procedure to avoid the potential problem.

Show/hide table

Image1

Image2

Image3

OWNER NOTIFICATION

Show/hide table

Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

Show/hide table

NOTE: This is a 1.0-hour job
Note: This is a 1 hour job for inspection only. One additional hour is allowed for the repair.

Show/hide table

PARTS DISPOSITION

Show/hide table

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Show/hide table

EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE STATOR LEADS ON CERTAIN C27 GENERATOR SETS EQUIPPED WITH 1200 FRAME (SR5) AND 590 FRAME (SR4B) GENERATORS

MODELS INVOLVED - C27

Dear Cat Product Owner:

The stator leads needs to be inspected on certain C27 Generator Sets equipped with 1200 Frame (SR5) and 590 Frame (SR4B) Generators. There is a potential for stator cable chafing against the sharp edge of the generator control cabinet and eventually causing a short to frame failure. This failure, in conjunction with other factors, may result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 11Jun2014 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 11Jun2014 Service Letter

Rework Procedure

Show/hide table

1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. 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 operation and disconnect/lockout all power sources before commencing any work.

2. Locate and remove the rear cover (see Image 1)

3. Proceed by:

3.1. Removing any tie straps from the lead cables (see Image 2 or 3 for reference)

3.2. Group the cables together so that there will be a minimum clearance of 3/4" (19mm) from all edges of the rear panel and no less than 3/8" (10mm) from the threaded inserts.

3.3. Attach new tie straps around the cables

3.4. Push on the cables to ensure that they cannot be easily moved and still maintain the appropriate clearance.

4. Reinstall the cover and restore the unit to its operational condition.