PRODUCT SUPPORT PROGRAM FOR REPLACING CURRENT TRANSFORMER COILS (CT COILS) ON CERTAIN C4.4, AND C7.1 MARINE GENERATOR SETS Caterpillar
PRODUCT SUPPORT PROGRAM FOR REPLACING CURRENT TRANSFORMER COILS (CT COILS) ON CERTAIN C4.4, AND C7.1 MARINE GENERATOR SETS
Usage:
TEBE3297-00
Show/hide table
06Aug2015
U-415
A-297
D-351
O-357
TM-11
Show/hide table
Before/After
PRODUCT SUPPORT PROGRAM FOR REPLACING CURRENT TRANSFORMER COILS (CT COILS) ON CERTAIN C4.4, AND C7.1 MARINE GENERATOR SETS
4476
PS44824
Show/hide table
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 "PS44824" 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.
Show/hide table
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.
Show/hide table
Show/hide table
Show/hide table
Show/hide table
TERMINATION DATE
31Aug2017
PROBLEM
Show/hide table
The existing CT Coils can display incorrect current on the control panel (monitoring device). The generator may not perform as expected on certain C4.4, and C7.1 Marine Generator Sets. If the existing CT Coils are not replaced it can/will show incorrect values on the control display panel.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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
Replace incorrect CT Coils with the correct CT Coils. Refer to the attached Rework Procedure.
Show/hide table
SERVICE CLAIM ALLOWANCES
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-4000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 1
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-4000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 2
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-4000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 3
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-4000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 4
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 5*******
0-4000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 5
Show/hide table
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 6*******
0-4000 hrs, 0-24 mo
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
NOTE: This is a 1.0-hour job for Group 6
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
WARNING: Ensure that all lockout/tag-out 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 AC and DC power supplies before starting work.
Refer to the appropriate Schematic, UENR3999, "C4.4 Marine Generator Set Electrical System" or Schematic, UENR3998, "C7.1 Marine Generator Set Electrical System for wire identification and connections of the AC Harness and replace each coil as required.
1. Remove the top cover from the generator exposing the terminals.
2. Disconnect the main AC cables (L1, L2, L3)
3. Note the direction of the arrows on the CT Coils. And their ratios. Refer to Image 1.1.1.
4. Replace the CT coils ensuring the spade terminal connectors go back on the corresponding connectors, and the arrows on the CT Coil labels are as per noted in the previous step
5. Coil L1 cable 73 on S1 cable 76 on S2 Coil L2 cable 75 on S1 cable 76 on S2. Coil L3 cable 77 on S1 cable 76 on S2. Refer to schematics. Ensure CT coils are secured to prevent damage from vibration. Refer to Image 1.1.2.
6. Reconnect the main AC cables L1, L2, & L3.
7. Tighten the terminal nuts to the following torque. - C4.4 M10 20Nm - C7.1 M12 35Nm
8. Replace terminal cover.
Group 1: Remove 3 of CT Coils 4578670 and replace with 3 of Coils 2683148 Remove 1 of Droop coil 2736237 and replace with 1 of Coil 2736241 Secure coils as required.
Group 2: Remove 3 of CT Coils 2683179 and replace with 3 of Coils 2736240 Remove 1 of Droop coil 2736238 and replace with 1 of Coil 2736239 Secure coils as required.
Group 3: Remove 3 of CT Coils 2683148 and replace with 3 of Coils 2765179 Remove 1 of Droop coil 2736241 and replace with 1 of Coil 2765181 Secure coils as required.
Group 4: Remove 3 of CT Coils 2736240 and replace with 3 of Coils 4578670 Remove 1 of Droop coil 2736239 and replace with 1 of Coil 2736237 Secure coils as required.
Group 5: Remove 3 of CT Coils 3088392 and replace with 3 of Coils 3088394 Remove 1 of Droop coil 3410977 and replace with 1 of Coil 3356777 Secure coils as required.
Group 6: Remove 3 of CT Coils 3088395 and replace with 3 of Coils 3088396 Remove 1 of Droop coil 3356778 and replace with 1 of Coil 4830256 Secure coils as required.
