PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE HARNESS, LOAD CABLES AND GROUND CABLES ON CERTAIN XQC1600 POWER MODULES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE HARNESS, LOAD CABLES AND GROUND CABLES ON CERTAIN XQC1600 POWER MODULES

Usage:

TEBE8394-00

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02Jan2019

U-1

A-1

D-1

O-1

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Before/After	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE HARNESS, LOAD CABLES AND GROUND CABLES ON CERTAIN XQC1600 POWER MODULES
1408 4459		PS46101

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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 "PS46101" 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

31Jan2021

PROBLEM

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The existing harness and cable insulation may rub and chafe against the frame or other cables on certain XQC1600 Power Modules. If the existing harness and cable insulation rub and chafe it can damage the insulation exposing copper. Rework of the harness and cables may be required.

AFFECTED PRODUCT

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Model	Identification Number
XQC1600	N1M00102-00116, 118-220, 222-306, 308-309, 311-315

PARTS NEEDED

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Qty	Part Number	Description
1	1P0810	TAPE-VINYL (After Failure Only)
8	7H8213	MAT-BAT BASE (After Failure Only)
30	7K1181	STRAP-CABLE (After Failure Only)
1	2006345	MOUNT-SWIVEL (After Failure Only)
1	TAPE1	THOMAS & BETTS CO TBFT201-36 (Qty as Needed)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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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 this product's 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, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is 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 or 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.

ACTION REQUIRED

Remove terminal box access covers and inspect the harness and the cable insulation for fouling and possible damage. Refer to Image 1 through Image 5.

If there are no fouling issues or damage to the insulation, re-install terminal box access covers and return to service.

If fouling or damaged insulation is observed, refer to the attached Rework Procedure.

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Image1

Image2

Image3

Image4

Image5

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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 0.5-hour job
0.5 hour to inspect, An additional 1.0 hour is allowed for cable and harness rework. The Thomas & Betts CO TBFT201-36 self infusion tape should be procured locally. Include the tape at cost. Retain a copy of the invoices in the Power Module folder for audit purposes.

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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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1. Remove control box side and rear panel. Store hardware for reuse.

2. Inspect harness and load cables and ground cables for fouling against other cables or metal surfaces.

3. If fouling is observed on the load cables, reposition the load cables and apply battery mat, 7H-8213 and secure with tie straps, 7K-1181. See Image1.1.1 and Image1.1.2 Note: Ensure battery mat ridges are on the outside and not making contact with the cables.

4. If fouling is observed on the ground cables, reposition the ground cables and secure with a tie straps, 7K-1181. See Image1.1.3, Image1.1.4, and Image1.1.5

5. If fouling is observed between the two hoses, install hose clamp, 200-6345 to separate. See Image1.1.6

6. If fouling is observed on the harness, reposition on ladder clips and secure with tie straps,7K-1181. See Image1.1.7, Image1.1.8, and Image1.1.9

7. If insulation damage has occurred resulting in exposed copper, Wrap the area of the damaged insulation with the Thomas & Betts Co TBFT201-36 insulation tape. Follow the instructions below for applying the tape.

a. Cut an easy to handle length of tape and stretch the tape over the damaged cable until the width of the tape is reduced by half.

b. Wrap along the center-line with as much tension as possible. When the tape touches the previous layer, the tape will stick and hold.

c. Extend the tape a minimum of 32 mm (1.25 inch) over the damaged insulation. For additional layers, use less tension and, stretch the tape until the width of the tape is reduced by one quarter inch.

8. Wrap the 1P-0810, vinyl electrical tape over the Thomas & Bets Co TBFT201-36 insulation tape.

9. Install control box access panels with stored hardware.

10. Return to service.