PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR 3890806, GEN, LAS, 40 L7 (2.2 SINGLE PHASE) OR 4159861, GEN, LAS 40 L7 (2.2 THREE PHASE) ON CERTAIN C2.2 MARINE GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR 3890806, GEN, LAS, 40 L7 (2.2 SINGLE PHASE) OR 4159861, GEN, LAS 40 L7 (2.2 THREE PHASE) ON CERTAIN C2.2 MARINE GENERATOR SETS

Usage:

TEBE2403-00

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19Mar2015

U-118

A-83

D-100

O-98

TM-2

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR 3890806/">3890806, GEN, LAS, 40 L7 (2.2 SINGLE PHASE) OR 4159861, GEN, LAS 40 L7 (2.2 THREE PHASE) ON CERTAIN C2.2 MARINE GENERATOR SETS
4450		PI11014

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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 as soon as possible. When reporting the repair, use "PI11014" 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 "PI11014" 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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PROBLEM

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The generator needs to be replaced on certain C2.2 Marine Generator Sets. The existing generator rotor can rub the stator. It will at first be noisy and could be mistaken for worn/damaged bearings. It may cause overheating of the windings of both the rotor and the stator. Failure of this major component 'the generator' could put other ships systems/operations at risk of malfunction. It 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
*****Group 1*****
C2.2	TAG01172, 1191, 1195-1196

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*****Group 2*****
C2.2	TAG01173-01174, 1180, 1193, 1198, 1203

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*****Group 3*****
C2.2	TAG01155, 1158-1162, 1176, 1178-1179, 1183-1186, 1188-1190

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*****Group 4*****
C2.2	TAG01177, 1181-1182, 1192, 1194, 1197

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2305772	GASKET
2	2455937	PLUG
1	3890807	GENERATOR
1	4734525	KIT-SERVICE
1	4750136	HOSE-AIR INLET
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.
*****Group 2*****
1	2305772	GASKET
2	2455937	PLUG
1	4159863	GENERATOR
1	4734525	KIT-SERVICE
1	4750136	HOSE-AIR INLET
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.
*****Group 3*****
1	2305772	GASKET
1	3890807	GENERATOR
1	4734527	KIT-SERVICE
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.
*****Group 4*****
1	2305772	GASKET
1	4159863	GENERATOR
1	4734527	KIT-SERVICE
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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Replace the generator.

3890806 LSA 40L7 (C2.2, Single phase) Generator and replacing it with 3890807 LSA 42.3 VS3 (C2.2T Single phase) Generator

4159861 LSA 40L7 (C2.2 Three phase) Generator and replacing it with 4159863 LSA 42.3 VS3 (C2.2T Three phase) Generator

Rework Procedure:
WARNING: Ensure that all lockout/tagout procedures for the site are followed.
Read and understand the Safety Section in the Operation and Maintenance Manual.
Ensure the area is safe and free from unwanted potential hazards. Isolate the battery and mains voltage before starting work.

Refer to the Disassembly and Assembly, RENR7859 for removal and installation instruction of the Generator/Alternator.

The mounting hardware service kit required is dependent on the machine group being worked on, OPEN or ENCLOSED Generator Sets. Replace all of the original hardware with the kit.

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OWNER NOTIFICATION

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

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 4.0-hour job for Group 1

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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 4.0-hour job for Group 2

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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 5.0-hour job for Group 3

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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 5.0-hour job for Group 4

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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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR 3890806/">3890806, GEN, LAS, 40 L7 (2.2 SINGLE PHASE) OR 4159861, GEN, LAS 40 L7 (2.2 THREE PHASE) ON CERTAIN C2.2 MARINE GENERATOR SETS

MODELS INVOLVED - C2.2

Dear Cat Product Owner:

The generator needs to be replaced on the products listed below. The existing generator rotor can rub the stator, which may cause overheating of the windings. Failure of the generator could put other ship systems/operations at risk of malfunction, and 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 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 19Mar2015 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 19Mar2015 Service Letter