PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BATTERY CHARGER ON CERTAIN 3306B, 3406C, 3412C, 3456, G3406, AND G3412 GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BATTERY CHARGER ON CERTAIN 3306B, 3406C, 3412C, 3456, G3406, AND G3412 GENERATOR SETS

Usage:

SEBE9431

December 14, 2005
U-393
A-292
D-309
O-329

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BATTERY CHARGER ON CERTAIN 3306B, 3406C, 3412C, 3456, G3406, AND G3412 GENERATOR SETS
1401		PI30896

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30896" 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 "PI30896" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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
June 30, 2006	December 31, 2006

PROBLEM

From the period of May 2004 through December 2004, the incorrect battery charger may have been installed on Griffin packaged engine generator sets. Orders requiring a 120 VDC, 60 Hz, UL Listed battery charger with alarms may have received a 230 VDC, 50/60 Hz, battery charger with alarms.

AFFECTED PRODUCT

****Group 1****

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Model	Identification Number
3306B	B8D685, 687, 694, 697-698, 704-705, 708, 710, 712, 720-723, 725-726, 731, 734-735, 737, 741, 743-744, 746-747, 749-750, 757-758, 760, 764-766, 768, 770, 773, 781, 784-785, 787-789, 792-793, 797, 810, 814, 820, 823
3406C	KPS1526, 1545, 1558, 1567-1568, 1578, 1580, 1584, 1588-1592, 1594-1595, 1599, 1602, 1606-1607, 1613, 1618, 1632, 1636, 1640-1642, 1644-1645, 1648, 1652, 1660, 1662, 1664-1665, 1669-1670, 1675-1678, 1680-1682, 1685, 1687, 1695, 1698, 1701-1702, 1710-1711, 1720-1722, 1725, 1732-1733, 1743, 1745, 1753, 1821, 1831, 1834-1835, 1840
G3406	KAR307, 311, 317, 323-324, 328, 331, 333

****Group 2****

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Model	Identification Number
3456	CBX675, 679-680, 684, 689, 692-694, 699, 701, 703, 705, 708, 713, 725, 731, 743 CCB1121, 1125-1129, 1134-1135, 1137-1138, 1148, 1186-1187, 1191, 1200, 1202-1204, 1209, 1211-1212, 1222-1223, 1225, 1227-1228, 1230, 1235, 1239, 1242, 1249-1250, 1260-1261, 1268, 1270, 1272-1273, 1281-1283, 1285-1286, 1291, 1293
3412C	9EP3209-3210, 3213, 3216, 3221, 3227, 3239-3240, 3242, 3247, 3254, 3258, 3261, 3265, 3274, 3277, 3279, 3286, 3290-3291, 3294, 3323, 3336, 3349-3350, 3352-3354, 3360, 3365, 3367-3368, 3377 BCW818-820, 828-829, 834-836, 839, 841, 843, 847, 851 DJN204-205, 207, 213-217, 222, 226, 232, 241-242, 244, 246, 248, 269, 278, 283-284, 288, 292, 309-313, 317-320, 326, 328, 330, 343, 349, 356, 363-364, 368, 386, 388, 390, 393, 398, 405, 427-428 TFT145, 150, 154, 156, 162-163, 165, 167, 169-172, 177-178, 180-181, 190-191, 194-195
G3412	KAP281, 297-298

PARTS NEEDED

****Group 1****

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Qty	Part Number	Description
1	1184304	CHARGER-BATTERY

****Group 2****

No parts are required for Group 2

ACTION REQUIRED

Group 1

Battery Charger 119-8978 must be replaced on 3306, 3406 & G3406 packages.

Group 2

Battery Charger 119-8978 can be rewired on 3412 (9EP, BCW, DJN & TFT), G3412 (KAP) and 3456 (CBX & CCB) packages. Refer to the Wiring Diagram below showing the charger connections for 120VAC or 240VAC.

To rewire the 119-8978 Battery Charger for 240VAC, remove the charger supply wire from terminal 131 and reconnect to terminal 142.

Note: If a UL Listed battery charger is required, Battery Charger 119-8978 must be replaced.

Illustration 1

Illustration 2

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%	1.0	0	0	0	0
NOTE: This is a 1.0 hour job for both Group 1 and Group 2.

PARTS DISPOSITION

Use packaging materials from the new charger to return the incorrect charger. Mark the package exterior with enclosed charger part number (119-8978) and return to:

Caterpillar Inc.

445 Green Valley Rd

Griffin, GA 30224

Attn: Keith Jones

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

Attach. (1-Owner Notification)

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

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE BATTERY CHARGER

MODELS INVOLVED - CERTAIN 3306B, 3406C, 3412C, 3456, G3406, AND G3412 GENERATOR SETS

Dear Caterpillar Product Owner:

A new battery charger may need to be installed on the products listed below. 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 December 14, 2005 when scheduling this service.

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

Caterpillar Inc.

Identification #(s)

Attached to December 14, 2005 Service Letter