PRODUCT IMPROVEMENT PROGRAM FOR REWORKING CERTAIN ELECTRICAL SYSTEMS AND COMPONENTS AND THE REAR DOORS ON CERTAIN XQ125 GENERATOR SETS

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING CERTAIN ELECTRICAL SYSTEMS AND COMPONENTS AND THE REAR DOORS ON CERTAIN XQ125 GENERATOR SETS - MULTIPLE REPAIRS

Usage:

TEBE7976-00

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06Sep2018

U-518

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Priority	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING CERTAIN ELECTRICAL SYSTEMS AND COMPONENTS AND THE REAR DOORS ON CERTAIN XQ125 GENERATOR SETS - MULTIPLE REPAIRS
1021 1408 4459 7553		PI32935

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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 "PI32935" 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 "PI32935" 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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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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COMPLETION DATE	TERMINATION DATE
31Mar2019	30Sep2019

PROBLEM

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Certain XQ125 Generator Sets need to be reworked due to some assembly issues at the factory.

AFFECTED PRODUCT

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Model	Identification Number
XQ125	CK500100, 102-105, 107, 110, 143-221

PARTS NEEDED

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Qty	Part Number	Description
2	1H3338	LOCKWASHER
1	2L8077	TERMINAL
10	3S2093	STRAP-CABLE
1	4_AWG_GREENYELLOW_2M	4 AWG GREENYELLOW 2M
1	8M8948	FUSE-15 AMP
1	8T4183	BOLT-HEX HEAD
1	8T4223	WASHER-HARD
1	8T4971	BOLT
1	9G2731	HOLDER AS-FUSE
1	9W0844	SOCKET-CONNECTOR
2	9X2038	WASHER-HARD
1	14_AWG_RED_350CM	14 AWG RED 350CM
1	1293178	LOCKNUT-THIN
1	1293180	LOCKNUT-JAM
2	2066875	CAP-TUBE
2	2140910	LOCKWASHER
330	2895150	SLEEVE BK-ELEC
1	4808216	CABLE AS
1	KOPR_SHIELD	KOPR SHIELD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 44% 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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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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

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 2.0-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.

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING CERTAIN ELECTRICAL SYSTEMS AND COMPONENTS AND THE REAR DOORS - MULTIPLE REPAIRS

MODELS INVOLVED - CERTAIN XQ125 GENERATOR SETS

Dear Cat Product Owner:

Certain electrical systems and components and the rear doors need to be reworked on the products listed below. 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. Please refer the dealer to their Service Letter dated 06Sep2018 when scheduling this service.

We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 06Sep2018 Service Letter

Rework Procedure

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ACTION REQUIRED
Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in the Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, on the product, and in the OMM are not all inclusive. If a tool, procedure, work method, or operating technique not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.
The user should ensure that the product will not be damaged and that the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated mechanically and electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

***Remove 30A fuses and stud cap install***

Access the 30 amp fuse installed in the generator set enclosures. If a 30 amp fuse 274-9872 installed in the incorrect location per Image 1.2.1, remove it.

Image 1.2.1, shows the fuse in place, this is incorrect
Image 1.2.2 is correct it shows the fuse removed

Image1.2.1

Image1.2.2

Once you have both the 30 amp fuses are removed as shown in Image 1.2.2, install 2 caps 2066875 over the studs.

Image 1.3.1, shows the caps in place

Image1.3.1

***Connection Bus Bar Gp. Incorrectly Installed***

No parts needed for this section of work.

Remove steel washer from between ground and neutral cables and customer ground connection bus bar (2 places). Reinstall with washer between cables and nut.

The 8T4223 should never be between the bus bar and the cable lug.

Use Images 1.4.1 and 1.4.2 to assist you.

Image1.4.1

Image1.4.2

***Incorrect harness revision installed***

Part needed
4 AWG Ground cable

The harness assembly 525-6275 terminal wiring may have had the wrong engineering change level revision improperly installed and or missing wires. Move the 14 AWG conductor from its current location to the slot next to it shown in Image 1.5.1. Then place the 4 AWG conductor into the slot that was previously used by the 14 AWG conductor. This 4 AWG will need to travel from the breaker to the distribution block.

Use Images 1.5.1, 1.5.2, and 1.5.3 to assist you.

Image1.5.1

Image1.5.2

Image1.5.3

***NH3 Ammonia Sensor power supply wire is missing***

Parts required are the following:
Wire (14ga)
9G-2731 Holder-Fuse
8M-8948 Fuse-15A
2L-8077 Terminal-Ring
9W-0844 Socket (DT-14ga)
3S-2093 Tie Strap

Power supply wire for the NH3 sensor is missing. After 2.5 hours above 50% load a 1235-9 J1939 network #3 abnormal update rate fault code will become activate and emission alarm light will flash. After 5 hours the package will go into inducement and derate causing a package shut down. Install a 14 AWG wire, sleeve and fuse between position 54 on engine 70 pin connector and switched side of center relay on relay box.

Use image 1.6.1 to reference the parts needed for this rework.

Image1.6.1

1. Cut 4-in. of 14 AWG wire
2. Strip wire proper length for fuse holder (9G-2731) & crimp to wire.
3. Strip other end of 4-in. wire for ring terminal (2L-8077) & crimp to wire.
4. Cut 115-in. piece of 14ga wire
5. Strip one end of wire for opposite end of fuse holder & crimp on.
6. Strip opposite end for installation to Deutsch terminal (9W-0844) & crimp on.
7. Install fuse (8M-8948) in fuse holder.
8. Add sleeve (289-5150) to fully cover wire from fuse holder to DT terminal.

Image1.7.1

Using Image 1.7.1 as a reference.

Assemble ring terminal to DCU relay stud shown.
Middle Relay (457-2324)
Connect to Switched side of Relay (Right Post)

Image1.8.1

Using Image 1.8.1 as a reference.

Route new Wire As. as shown in red.

Secure Wire As. to Engine Harness with tie straps (3S-2093) to prevent contact with other components.

Image1.9.1

Image1.9.2

Using Image 1.9.1 and 1.9.2 as a reference.

Route new Wire As. as shown in red.

Insert 9W-0844 Terminal into Position 54 of 70-pin Engine Interface connector highlighted in Image 1.10.1.

Image1.10.1

***Rear Door Seal PN 474-9649 Improperly Installed***

Rear doors are installed with an extra section of seal making it difficult to latch the doors. Seal on back side of left rear door needs to be removed.

Use Images 1.11.1 and 1.11.2 as references.

Image1.11.1

Image1.11.2

***Tank Ground Missing***

The tank ground may be missing. Install ground cable between generator left foot and the left generator mounting pad.

Parts required are the following:
0950827 LOCKWASHER
1293178 LOCKNUT-THIN
1293180 LOCKNUT-JAM
2140910 LOCKWASHER
4808216 CABLE AS
8T4183 BOLT-HEX HEAD
8T4223 WASHER-HARD
8T4971 BOLT
9X2038 WASHER-HARD
Kopr-shield or Loctite Graphite-50 Anti-Seize compound

Image1.12.1

Ground location can be accessed through the left rear door of the package.

Image1.13.1

Remove and dispose of existing bolt from left generator foot. The existing hole in the left generator mounting pad will be used for the connection to the tank.

Image1.14.1

Grind area around each hole to achieve bare metal

Image1.15.1

Apply Thomas & Betts CP8-TB Kopr-Shield compound or Loctite Graphite-50 Anti-Seize compound to ground location to improve conductivity.

Image1.16.1

Install 480-8216 cable assembly. Use one 8T-4971 bolt, two 9X-2038 washers and one 129-3178 locknut at location on left generator foot. Tighten to 12 +/-3 Nm. Use one 8T-4183 bolt, two 8T4223 washers and one 129-3180 locknut at left generator mounting pad location. Tighten to 100 +/- 20 Nm. Ensure washers under bolt head are between bolt and generator lug. Washers must not be placed between lug and bare metal surfaces.