PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE POSITION OF TERMINAL CONNECTION LEADS INSIDE THE GENERATOR BOX ON CERTAIN C18 XQ600 Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE POSITION OF TERMINAL CONNECTION LEADS INSIDE THE GENERATOR BOX ON CERTAIN C18 XQ600

Usage:

REBE2275-00

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18Sep2007

U-461

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE POSITION OF TERMINAL CONNECTION LEADS INSIDE THE GENERATOR BOX ON CERTAIN C18 XQ600
4460		PI10626

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10626" 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 "PI10626" 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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The positions of copper terminals on the rail inside of the generator terminal box need to be reworked to prevent cables short-circuiting through the generator barrel on certain C18 XQ600 units. The existing positions of copper terminal on the rail may result in a short circuit failure, which may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
C-18	G4C01884, 2116, 2139, 2144, 2216, 2231

PARTS NEEDED

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Qty	Part Number	Description
1	7H8213	MAT-BAT BASE
3	7K1181	STRAP-CABLE
12	8T4133	NUT
12	8T4139	BOLT
12	8T4223	WASHER-HARD
6	8T5414	STUD-TAPERLOCK
1	9S3263	COMPOUND
24	1247346	LOCKWASHER-TOOTH
12	1518754	BOLT-HEX HEAD
48	2140910	WASHER-SPRING
12	2384743	WASHER

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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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%	100%	0%	0%	0%	0%

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NOTE: This is a 4.0-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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE POSITION OF TERMINAL CONNECTION LEADS INSIDE THE GENERATOR BOX ON CERTAIN C18 XQ600.

MODELS INVOLVED - C18 XQ600

Dear Caterpillar Product Owner:

The positions of copper terminals on the rail on the inside of the generator terminal box needs to be reworked to prevent cables short-circuiting through the generator barrel on certain C18 XQ600 units. The existing positions of copper terminals on the railmay result in a short circuit failure, which may result in personal injury or death. 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 18Sep2007 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 18Sep2007 Service Letter

Rework Procedure

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Instructions

1. Reference.
RENR8643 Disassembly & Assembly C18 Generator set.
SEBU7898 Operation & Maintenance manual C18 Generator

2. Isolate Genset before commencing any work on the unit, activate
emergency stop, open Genset breaker and disconnect battery cables.
Ensure health and safety requirements are adhered to at all times.

3. Remove generator top cover from terminal enclosure. See Image 1.1.1

Image1.1.1

4. Remove bolts connecting aluminium gland plate to generators terminal enclosure see Image 1.2.1

Image1.2.1

5. Disconnect cables L9, L8, and L7 (in that order) from top copper terminals see Image 1.3.1.

Image1.3.1

6. Disconnect cables L6, L5, and L4 (in that order) from bottom copper terminals see Image 1.4.1

Image1.4.1

7. Pull cables and gland plate away from the generator to facilitate access to Terminal rail assembly.

NOTE: Do not loosen cable glands. See Image 1.5.1.

Image1.5.1

8. Terminal rail assembly (shown in isolation for purposes of clarity)Image 1.6.1.

Image1.6.1

9. Disconnect copper terminals from terminal rail and remove stand off insulators Image 1.7.1

Image1.7.1

10. Bolt on stand off insulator for Neutral Bar Image 1.8.1.

Image1.8.1

11. Bolt on stand off insulators using M12x30 studs. Secure with thread lock adhesive and shake proof washers Image 1.9.1.

Image1.9.1

12. Connect copper terminals to stand off insulators Image 1.10.1.

Image1.10.1

13. Re-connect cables to copper terminals as per Image 1.11.1 and 1.11.2.

Image1.11.1

Image1.11.2

14. Wrap neutral cables with ribbed rubber mat. Secure with Cable ties Image 1.12.1.

Image1.12.1

15. Refit gland plate to generator terminal enclosure.

16. Refit alternator top cover plate to generator terminal enclosure.

17. Clear generator area, reconnect batteries, and release emergency
stop and clear emergency stop fault code.

18. Run functional No load test on Genset
References:
SEBU7898 Operation & Maintenance manual C18 Generator