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

Usage:

TEBE7216-00

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15Feb2018

U-93

A-73

D-87

O-88

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REWORK OF THE STATOR LEADS ON CERTAIN C27 GENERATOR SETS EQUIPPED WITH 1200 FRAME (SR5) GENERATORS
4453 1404 4460		PI11136

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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 "PI11136" 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 "PI11136" 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 stator leads needs to be inspected on certain C27 Engine Generator Sets equipped with 1200 Frame (SR5)generators. There may be opportunity for stator lead chafing against the sharp edge of the generator control cabinet, which may 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

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Model

Identification Number

C27

2A300101-00125, 127, 129-153, 155, 157-169, 171-198, 201-212, 214-233

GDS00102, 385, 388-389, 391, 393, 402-404, 408-410, 412-428, 433, 437, 439-449, 451, 477-504, 508, 521-522, 527, 529-536, 538-541, 544-551, 553, 561-563, 565-568, 571-573, 576-594, 596-614, 616-624, 626-642, 645-646, 650-658, 660, 662, 664, 666-670, 672-674, 676-680, 685-687, 689-711, 713-725, 727-788, 791-792, 794, 797-811, 813, 815-829, 831, 834, 836-848, 850-868, 870-888, 890, 892-903, 905-906, 908-911, 913-921, 923-930, 932, 934-940, 943-958, 960-963, 965-973, 975-977, 980, 982-986, 989-1026, 1028-1035, 1037-1054, 1056-1058, 1060-1066

PARTS NEEDED

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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

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Inspection Procedure

1. Isolate the engine generator set before commencing any work on the unit. Lock open the generator breaker, activate the 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 unit. Lock out engine generator set operation and disconnect and 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, i.e. check all direction. The clearance should be at least 3/4" (19mm). For reference see Image 2.

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, then as a minimum confirm that the clearance is at least 3/8" (10mm)). For reference see Image 2.

5. If the stator leads 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 stator leads are properly secured with tie straps, then reinstall the cover and restore the unit to its operational condition.

6. If the stator leads are already located within or can be moved within 3/4" (19mm) between the leads and the sharp edge of the rear control cabinet or to within 3/8" (10mm) between the leads and threaded inserts, then there may be opportunity for future stator lead chafing against the sharp edge of the generator control cabinet or threaded inserts, which may eventually cause a short to frame failure. Perform the Rework Procedure. Dealer is requested to submit before/after pictures with the claim in SIMSi.

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Image1

Image2

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 0.5-hour job
Note: This is a 0.5 hour job for inspection only. When applicable, one additional hour is allowed for the repair.

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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 THE INSPECTION AND POSSIBLE REWORK OF THE STATOR LEADS ON CERTAIN C27 GENERATOR SETS EQUIPPED WITH 1200 FRAME (SR5) GENERATORS

MODELS INVOLVED - C27

Dear Cat Product Owner:

The stator leads need to be inspected on certain C27 Engine Generator Sets equipped with 1200 Frame (SR5) generators. There may be opportunity for stator lead chafing against the sharp edge of the generator control cabinet, which may eventually cause 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 DATE when scheduling this service. Please refer the dealer to their Service Letter dated 15Feb2018 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to 15Feb2018 Service Letter

Rework Procedure

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1. Isolate the engine generator set before commencing any work on the unit. Open generator breaker, activate Emergency Stop, disconnect 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 engine 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 stator leads (see Image 2 for reference).

3.2. Group the stator leads 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 stator leads.

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

3.5 If the minimum clearance from metal frame cannot be met, have the Dealer Technical Communicator (TC) submit a request for further instructions to CPI 323457 through CPI Feedback within the Service Information Management System (SIMSi).

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