PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGING ALTERNATOR WIRE ON CERTAIN XQ200 POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGING ALTERNATOR WIRE ON CERTAIN XQ200 POWER MODULES

Usage:

TEBE1610-00

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04Aug2014

U-460

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGING ALTERNATOR WIRE ON CERTAIN XQ200 POWER MODULES
1405 1408		PS44432

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

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 "PS44432" 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

31Aug2016

PROBLEM

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The existing charging alternator wire can fail on certain XQ200 power modules. The existing 14 awg wire needs to be replaced with 8 awg wire and terminals.

AFFECTED PRODUCT

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Model	Identification Number
C7.1	MRP00100-00127, 129-278

PARTS NEEDED

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Qty	Part Number	Description
1	2L8061	TERMINAL
1	5P3455	TERMINAL
1	5P5689	WIRE-ELECTRICAL
4	1193662	TUBE-BULK
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% 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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In order to prevent possible failure of the alternator wire the existing 14 awg wire needs to be replaced with 8 awg wire and terminals.

"See the attached Rework Procedure."

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Image1

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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Refer to the Service Manual if/as necessary.

WARNING: Injury can occur to personnel if the rework is done improperly. Personal Protective Equipment (PPE) suitable to the work being performed must be worn when performing the rework.

WARNING: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energization or start up of the power module. Failure to follow these warnings could result in injury to personnel during service.

Remove both connectors from the black conduit shown in Image1.1.1

Image1.1.1

Route 1 meter of 8 awg 5P-5689 Wire inside the conduit from charging alt to starter terminal.
Install the terminals to the end of wire. Reinstall the conduit connectors.

Parts Required
1 M 5P-5689 Wire
1 5P-3455 Terminal
1 2L-8061 Terminal

Image1.2.1

Disconnect the 14 awg '+' white wire from the alternator. Remove the terminal and discard. Cap the wire with heat shrink tube and store inside conduit.

Parts Required
4 CM 119-3662 Tube