PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE EARTH/GROUND CABLE ON CERTAIN C1.5 AND C2.2 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE EARTH/GROUND CABLE ON CERTAIN C1.5 AND C2.2 GENERATOR SETS

Usage:

TEBE8860-00

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06Mar2019

A-82

O-92

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Safety	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REWORKING THE EARTH/GROUND CABLE ON CERTAIN C1.5 AND C2.2 GENERATOR SETS
7423 1404 1405		PI11203

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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 "PI11203" 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 "PI11203" 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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Certain C1.5 and C2.2 Generator Sets may have the main AC alternator wired incorrectly. The earth/ground cable that is secured onto the terminal plate inside the AC alternator control box may be located incorrectly.

This alternator failure 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*****
C1.5	TYC00168-00231, 233-235

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*****Group 2*****
C2.2	TY200595-00599, 601-602, 657, 681, 736, 768-796, 799-807, 811-812, 815-823, 1025-1026, 1028, 1036-1045, 1051-1064, 1067-1068, 1071

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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The earth/ground cable needs to be inspected and reworked if it is found to be located incorrectly. 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
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 1.0-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 1.0-hour job for Group 2

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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 INSPECTING AND POSSIBLY REWORKING THE EARTH/GROUND CABLE

MODELS INVOLVED - CERTAIN C1.5 AND C2.2 GENERATOR SETS

Dear Cat Product Owner:

The ground cable needs to be inspected and possibly reworked on the products listed below. The existing ground cable wiring configuration can result in the failure of the alternator, which 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 CAT.COM/SAFETY website and click on SUPPORT, then SAFETY SERVICES for more information. Please refer the dealer to their Service Letter dated 06Mar2019 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 06Mar2019 Service Letter

Rework Procedure

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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 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 and the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Isolate the Genset before commencing any work on the unit, open Genset breaker, activate Emergency Stop, turn off the fuel supply to the genset and disconnect battery cables.

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 generator before commencing any type of work.

Only qualified electrical personnel should service this equipment.

1. Review the Generator Set data plate to determine the required and expected alternator output wiring configuration for the specific generator set being evaluated. The alternator wiring configuration will be one of three (3) possibilities; Single Phase-Two Wire, Single Phase-Three Wire or Three Phase-Four Wire.

2. Review illustrations (Image 1.3.1) (Image 1.3.2) (Image 1.3.3) and match the illustration to the expected alternator output wiring configuration determined in step 1.

Image1.3.1

Image1.3.2

Image1.3.3

3. Remove the Alternator Box Assembly cover to access the alternator configuration Terminal Plate.

4. Inspect the actual alternator output wiring configuration at the Terminal Plate and compare the observed wiring configuration to the illustration selected in step 2.

5. Ensure that the Yellow and Green striped Earth Cable is secured to the correct terminal point on the Terminal Plate as defined by the illustration selected in step 2.

6. If the Earth Cable is in the wrong location, relocate the Earth Cable to the correct terminal point on the Terminal Plate. Reuse the same hardware.

7. If the Earth Cable is in the correct location and all other alternator output wiring leads are correctly located, no further action is required.

8. Tighten the retaining terminal point hardware to 5Nm.

9. Install the Alternator Box Assembly cover.

10. Connect the Engine Starting Battery Conductors.

11. Turn On the Fuel Supply to the Generator set.

12. Deactivate the Estop switch.

13. Restore the Generator Set to it?s proper configuration and readiness status for customer use.

14. Task complete.