PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REPAIRING, OR REPLACING THE BRAIDED POWER CABLES ON CERTAIN 3406C, G3406C, C18, AND 3456 GENERATOR SETS Caterpillar

PROBLEM

1. Insulation exposing copper braid


Insulation may become exposed, during assembly or shortly afterwards, as shown in Figure 1. This is addressed in the solution below.



Figure 1

2. Insulation chaffing


The loom insulation may become damaged due to chaffing and/or scratches, either at assembly, during use, or during re-configuration of the genset in the field. This is shown in Figure 2. Additionally, the insulation may potentially become damaged through contact with the chassis metalwork, as shown in Figure 3, resulting in a short circuit to chassis. This is mainly a potential problem for the L3 phase cable. These are addressed in the solution below.



Figure 2



Figure 3

3. Loom termination fixing onto generator busbar


The insulation on the cable may come into contact between the generator busbar and the face of the cable terminal, as shown in Figure 4. This is addressed in the solution below.



Figure 4

4. Generator cables making contact with adjacent busbar


If there is excess length of the cable within the generator, it is possible that one cable may come into contact with an adjacent generator busbar. Over time, wear may occur, resulting in a short circuit between phases. See Figure 5. This is addressed in the solution below.



Figure 5

AFFECTED PRODUCT

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Model	Identification Number
3406C	C2G1-1223
3456	C3G1-191 C4G1-163 C1G1-626 C2T201-230
C18	G4C1-392
G3406C	C5G1-176

PARTS NEEDED

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Qty	Part Number	Description
12	7H-8213	MAT-BATTERY BASE
24	7K-1181	STRAP-CABLE (PLASTIC)
0.8 M	7X2639	TUBE-SHRINKABLE

TOOLS NEEDED

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Qty	Description
1	HOT-AIR GUN

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	2.0	0	0	0	0
NOTE: This is a 2.0 hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
        (2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REPAIRING, OR REPLACING THE BRAIDED POWER CABLES

MODELS INVOLVED - CERTAIN 3406C, G3406C, C18, AND 3456 GENERATOR SETS

Dear Caterpillar Product Owner:

The Braided Power Cables need to be inspected and reworked on the products listed below. If the inspection indicates a possible failure has occurred new Power Looms will be installed on your Generator Set. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated June 9, 2005 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to June 9, 2005 Service Letter

Rework Procedure

The required parts list provides additional protection for the power looms, which should prevent damage and potential hazard. These parts should be fitted to all power looms.

 

If there is existing damage to power looms, they should be replaced individually, using the appropriate parts from the optional parts list.

Note: That any replacement power looms should also have the parts on the required parts list fitted to provide the additional protection.

****Optional Parts****


 
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Qty	Part Number	Description
*	239-7814	BRAID-(COPPER) 630A / 1.65m
*	239-7815	BRAID-(COPPER) 630A / 1.85m
*	239-7816	BRAID-(COPPER) 630A / 2m
*	239-7817	BRAID-(COPPER) 800A / 1.65m
*	239-7818	BRAID-(COPPER) 800A / 1.85m
*	239-7819	BRAID-(COPPER) 800A / 2m
*	239-7820	BRAID-(COPPER) 1250A / 1.65m
*	239-7821	BRAID-(COPPER) 1250A / 1.85m
*	239-7822	BRAID-(COPPER) 1250A / 2m
*	239-7823	BRAID-(COPPER) 1600A / 1.65m
*	239-7824	BRAID-(COPPER) 1600A / 1.85m
*	240-2117	BRAID-(COPPER) 1600A / 2m
*	239-7825	BRAID-(COPPER) 2000A PTS / 1.525m
*	239-7826	BRAID-(COPPER) 2000A PTS / 1.75m

*NOTE: Optional parts depending on Gen Set configuration and degree of failure as outlined in the rework procedure.
 

1. Insulation exposing copper braid

1. Cut back the sleeve to expose approx 100mm (3.9 inches) of copper braid at each end. Use scissors or fine wire cutters. Do not use blade cutters. Care should be taken to prevent damaging the copper braids.
2. Fit 2 100mm (3.9 inches) lengths of heat shrinkable tubing (one at each end) to cover both the copper braid and the sleeving. The part number for the heat-shrinkable tubing is 7X2639 which has an internal diameter of 50.8mm (2 inches) before shrinkage and a minimum of 25.4mm (1 inch) after shrinkage.
3. Apply hot air to the heat-shrink tubing to shrink it securely on to both the braid and the sleeve. Be careful not to damage the sleeving in the process.

Figure 6

1. Generator looms making contact with adjacent busbar

1. To prevent the looms coming into contact with adjacent generator busbars, firstly add heat-shrink tubing as shown in Figure 6, if not already fitted. This should make the loom sufficiently stiff that it should not easily fall and come into contact with the adjacent busbar.
2. Using cables straps (part number 7K-1181), ensure that the looms are secured at a minimum of 10mm (0.39 inches) from the adjacent busbars.
3. If necessary, use cables straps (part number 7K-1181) to ensure that the phase and neutral looms will not be damaged through physical contact with other metal parts, such as generator studs.

1. Loom termination fixing onto generator busbar


Ensure that the screws are tightened to the following torque:
M6 8.9 lb (+/-2.2 lb) [12Nm (+/-3 Nm)]

M10 34.7 lb (+/-6.6 lb) [47Nm (+/-9 Nm)]
 

2. Insulation chaffing

1. Add 4 (part number 7H-8213) rubber mats to looms as they enter the control panel as shown in Figure 7 to better insulate the looms from the chassis.
2. Secure the mats to the looms with 8 (part number 7K-1181) cable straps.




Figure 7

3. Add 4 (part number 7H-8213) rubber mats to looms as they enter the turret as shown in Figure 8 to better protect the looms from chaffing.
4. Secure the mats to the looms with 8 (part number 7K-1181) cable straps.

 

 



Figure 8

5. Add 1 (part number 7H-8213) rubber mat to the center loom to insulate it from the other two phase looms, where the other two phase looms are cable-strapped to it, as shown in Figure 9. DO NOT secure the mat with a cable strap.

 

 



Figure 9

6. Add 1 or 2 (part number 7H-8213) rubber mats as required around the three phase looms, as shown in Figure 10.
7. Secure all the mats with 2 (part number 7K-1181) cable straps.

 






Figure 10

8. Add 1 (part number 7H-8213) rubber mat around the neutral loom where it meets the opening in the top of the alternator housing, as shown in Figure 11.
9. Secure the mat with 2 (part number 7K-1181) cable straps.

Figure 11