PRODUCT SUPPORT PROGRAM FOR REPLACING THE BATTERY CHARGER WIRE TERMINATIONS ON CERTAIN C1.5, C2.2, C3.3, C4.4, AND C6.6 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE BATTERY CHARGER WIRE TERMINATIONS ON CERTAIN C1.5, C2.2, C3.3, C4.4, AND C6.6 GENERATOR SETS

Usage:

REBE3905-00

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07Jul2008

U-359

A-291

D-295

O-329

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE BATTERY CHARGER WIRE TERMINATIONS ON CERTAIN C1.5, C2.2, C3.3, C4.4, AND C6.6 GENERATOR SETS
4450 1401 1406 1408 7451		PS51519

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51519" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31Jul2010

PROBLEM

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The existing wire terminations from the control panel to the battery charger and/or wire terminations on the built-in ammeter may be unreliable on certain C1.5, C2.2, C3.3, C4.4, and C6.6 generator sets.

AFFECTED PRODUCT

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Model	Identification Number
C1.5	NCA00350-00395, 397-421, 425, 427-428
C2.2	NCB00350-00407, 409-443, 446-455, 457-473, 477-492, 495-503, 505-599 XYE00350-00397, 404-445, 448-454, 456-475, 478-480, 482-485, 491-498, 508-527, 529-549, 551-559, 590-598, 600, 602-607, 611-620, 623-625, 628-629, 631-639, 644, 652-653, 656, 658, 661-664, 670-676, 678-680, 682
C3.3	N3C00100-00115, 117-126, 128-133, 137-151, 154, 157-193, 195-217, 219-229, 231-233, 236-238, 242-243, 245-253, 255-257, 259-260, 262, 266-268, 272, 275-276, 281, 284-286, 293-338, 340-385, 387, 389, 391-399, 500-517, 519-522, 526-536, 600, 603, 605-608, 610-642, 645-667, 670-677, 681-686, 688-699 N3X00100-00101, 103-126, 200-314, 316-317, 319-328, 330, 332-334 NCC00100, 104-124, 128-147, 149-158, 164
C4.4	D4B00402-00404, 412-415, 417-472, 474-511, 613-620, 622-655, 657-661, 663-693, 695-701, 802-876, 879, 882, 884-886, 889 N4D00100-00106, 108-117, 119-211, 213-215, 217-224, 226-309, 322, 324-338, 342-365, 367-377, 379-387, 389-392, 394-397, 399-428, 430-446, 448-527, 529-578, 580-592, 594-607, 609-649, 651-653, 655-681, 683-685, 687-693, 695-729, 830-885, 887-893, 895-900, 902-920, 922-937, 939-940, 942-949, 951-963, 967-974, 976-981, 983-1005, 1007, 1035-1070, 1072-1073, 1075-1084, 1086-1087, 1100-1137, 1139-1141, 1143-1199 N4E00100-00115, 117-133, 135-160, 162-592, 594-861, 863-962, 964-981, 983-999, 1100-1152, 1154-1176, 1178-1179, 1181, 1183-1189, 1192-1196, 1198-1199 N4R00200-00212, 300-355, 357-379, 381, 383-386, 400-402 N4X00100-00102, 200-273, 275-315, 317-320, 323-364, 367, 369-373, 375-385, 389-408, 410-413, 416-418, 420-422, 424, 426-428, 430, 432-437, 442-444 NCD00201-00463, 469-495, 497-567, 590, 600-614, 616-653, 655-841, 848-922, 924-996, 1002-1069, 1071-1155, 1179 NCE00201-00237, 239-300, 302-320, 322-336, 338-346, 348-626, 628-704, 706-745, 765-782, 784-795, 797-819, 823-839, 841 XYC00233-00297, 300-303, 305-466, 468-491, 504-657, 660-680 XYD00200-00298, 300-317, 319-328, 349-365, 367-414, 447-608, 614-622, 626-630, 636, 644-645
C6.6	N6D00100-00106, 108-126, 128-157, 159-160, 162-227, 231, 233, 236-302, 304-395, 397-410, 412, 414-651, 653-655, 657-661, 663-667, 669 SDA00109-00114, 117-119, 121-124, 126-134, 139-159, 161-162, 165-253, 262-294, 296-307, 310-332, 341-380, 384-387, 393-396, 400-402, 407-423, 426-435, 465-549, 564-566, 570-571, 582-593, 595-601, 608-609
OLYMPIAN	D4P00102-00248, 250, 254-257, 261-304, 306-319, 321-337, 340-684, 710-829, 850-1310, 1316, 1341-1379 GAL00101-00106, 116-119, 121, 124-129, 135, 138 NAT00100-00227, 229-466, 468-968, 970-982, 984-1056, 1058-1076, 1078-1280, 1282-1313, 1315-1323, 1325-1357, 1359-1461, 1463-1490, 1494-1514, 1516-1574, 1576-1595, 1597-1736, 1738-1748, 1750-1780, 1782-1798, 1800-1810, 1812-1859, 1863-1865, 1868-1875, 1879-1880, 1887-1888, 1907-1922, 1924-1949, 1952-1984, 1987, 1989, 1991-1992, 1994, 1999, 2007-2008, 2019-2023, 2025-2026, 2032 NFC00100-00474, 476-500, 502-659, 661-699, 701-710, 712-1083, 1085-1158, 1160-2307, 2309-2790, 2812-2860, 2869-2883, 2890-2899, 2910-2913, 2918-2923, 2934-2939, 2951-2966 NFS00100-00135, 137-199, 210-231, 233-235, 237-655, 657-738, 740-812, 814-1768, 1770-1802, 1810-1874, 1881-1915, 1951-2260, 2267-2296, 2301-2318, 2321-2331, 2333, 2338-2340, 2346-2350, 2353-2419, 2470-2518, 2520-2551, 2560-2572, 2574-2581, 2583-2587, 2602-2666, 2699-2723, 2726-2756, 2763-2765, 2767-2770, 2773-2793, 2841-2859 NGA00100-00199, 250-299, 400-459, 461-463, 465-472, 498-499 NGB00100-00136, 141-159, 161-187, 189-279, 281-282, 284-290, 292, 294, 323-349, 450-480, 482-499, 600-603, 605-607, 610-612, 614-615, 617-621, 625-649 NGC00100-00103, 105-109, 111-464, 466-496, 498-643, 645-652, 654-683, 685-699, 800-885, 887-1049, 1150-1293, 1298, 11886 NGD00100-00516, 518-647, 650-682, 684-1099, 1102-1103, 1106-1199 NGF00100-00198, 201-287, 289-348, 350-355, 357-654, 656-1059, 1061-1162, 1164-1179, 1181-1263, 1269, 1271, 1289-1302 NGG00100-00149, 600-608, 610-627, 629, 632-649, 699, 1050-1084, 1086-1099 NGJ00100-00199, 380-386, 388-449 NGT00101-00160, 162-382, 385-416, 418-428, 431, 433-439, 449, 455-457, 555-565, 569-578, 589-600 NNS00100-00433, 435-437, 439-577, 579-626, 628-644, 646-800, 802-808, 810-815, 817-1056, 1058-1062, 1064-1154, 1156-1193, 1196-1199, 1201-1202, 1204-1207, 1209-1248, 1250-1477, 1479-1513, 1515-1834, 1837-1899, 1950-1986, 1988-2286, 2288-2293, 2297-2540, 2546, 2548-2552, 2554, 2558-2588, 2590, 2595-2643, 2649, 2656-2659, 2661-2667, 2679-2681, 2687-2693, 2699-2700, 2707, 2713-2716, 2719-2720, 2725-2726, 2728-2731, 2735-2736 NPF00100-00125, 127-247, 249-250, 252, 254-376, 378-383, 385-701, 703, 705-1770, 1772-1948, 1950-1955, 1957-1980, 1982-2329, 2331-2492, 2494-2650, 2655-2705, 2709-2765, 2767-2825, 2827-2889, 2891-3086, 3088-3255, 3266-3457, 3459-3771, 3773-4636, 4690-4698, 4700-4703 NPS00100-00274, 276-753, 755-837, 839-843, 845, 847-851, 853-865, 867-1083, 1085-1089, 1091-1182, 1185-1359, 1361-1368, 1370-1602, 1604-1643, 1645-1839, 1841-1857, 1870-1876, 1881-1882, 1890-1896, 1898-1904, 1923-1961, 1963-2090, 2092, 2094-2116, 2119-2178, 2180-2181, 2183-2200, 2202-2218, 2220-2228, 2239-2240, 2244, 2246-2255, 2258-2272, 2275, 2277-2299, 2306, 2312-2313, 2315-2320, 2322-2325 RFT00101-00156, 160-198, 202-213, 218-227, 229

PARTS NEEDED

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Qty	Part Number	Description
2	2L8076	TERMINAL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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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The wire terminations need to be reworked/replaced. Refer to the attached Rework Procedure.

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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%
0-10000 hrs, 0-36 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

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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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TOOLS REQUIRED

Crimp tool for insulated crimp terminals
Flat-blade screwdriver (shaft and tip diameter maximum 3.5mm wide)

INSTRUCTIONS

1. Isolate Genset before commencing any work on the unit, activate emergency stop, open genset breaker, and disconnect battery cables. Ensure that the auxiliary mains supply are disconnected before starting work. Ensure health and safety requirements are adhered to at all times.

2. Remove the two screws securing the terminal cover plate and the four screws securing the ammeter cover.

3. Using the flat-blade screwdriver, remove the wires to the battery charger terminal block, using the method shown below:
Use the screwdriver to open the cage-clamp terminal by placing the screwdriver in the terminal as shown in Figure 1.1.1 below. To open the terminal, push directly down on the screwdriver.

NOTE: Do not pry with the screwdriver, it will not open the terminal.

Image1.1.1

4. Inspect the wires to ensure that there are no broken strands.

5. If necessary, cut 10mm off the end of the wire and strip 6mm of insulation from the wire.

6. Replace the wire into the terminal block, ensuring that it is fully pushed into the terminal and that there are no stray strands of wire exposed outside the terminal.

7. Remove the plastic covers on the ammeter terminals.

8. Remove the connectors from the ammeter terminals.

9. Cut off the connectors as close to the connectors as possible. Do not shorten the wires more than necessary.

10. Re-terminate using new terminals CAT part number 2L8076.

11. Re-connect the wires onto the ammeter, ensuring that the wire from the printed circuit board is connected to the + terminal on the ammeter and the wire to the terminal block is connected to the ? terminal on the ammeter.

12. Replace the plastic covers on the ammeter terminals.

13. Replace and secure the ammeter cover and the terminal cover plate.

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

15. Reconnect the auxiliary mains supply and test the battery charger for correct operation.