PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE GROUND STRAP ON THE DOSING CABINET ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE GROUND STRAP ON THE DOSING CABINET ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS

Usage:

REBE9691-01

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09May2013

(Revised 22May2013)

U-193

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE GROUND STRAP ON THE DOSING CABINET ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS
1408 1900 1091		PI32174

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32174" 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 "PI32174" 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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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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NOTE:	This Revised Service Letter replaces 09May2013 Service Letter. Changes have been made to the Affected Product.

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COMPLETION DATE	TERMINATION DATE
30Nov2013	31May2014

PROBLEM

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The dosing cabinet needs to be reworked on certain 3516C Generator Sets, and 3516C HD Generator Sets. The existing grounding in the dosing cabinet is not sufficient and additional ground straps are needed.

AFFECTED PRODUCT

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Model	Identification Number
3516C	SCJ00113-00114
3516C HD	SCK00117, 119-123 SFK00101-00104 SKC00101-00102

PARTS NEEDED

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Qty	Part Number	Description
1	2Y5829	NUT-HEX
3	5C2890	NUT-HEX
1	5P4115	WASHER-HARD
2	6V2315	BOLT-HEX HEAD
2	6V5839	WASHER-HARD
1	6V5842	BOLT-HEX HEAD
2	6V8214	BOLT-HEX HEAD
1	9X8267	WASHER-HARD
1	1085747	STRAP-GROUND
1	1461815	STRAP AS
1	1751540	BOSS-GROUND
1	2330059	FILM-GROUND
1	3018313	TERMINAL-BLOCK
1	3892139	WIRE AS-GROUND
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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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

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 3.0-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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE GROUND STRAP ON THE DOSING CABINET ON CERTAIN 3516C GENERATOR SETS, AND 3516C HD GENERATOR SETS

MODELS INVOLVED - 3516C, 3516C HD

Dear Cat Product Owner:

The dosing cabinet needs to be reworked on certain 3516C Generator Sets, and 3516C HD Generator Sets. The existing grounding in the dosing cabinet is not sufficient and additional ground straps are needed. 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.

Please refer the dealer to their Service Letter dated 09May2013 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 09May2013 Service Letter

Rework Procedure

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1. Isolate the generator set before commencing any work on the unit, open generator set breaker, activate Emergency Stop, disconnect the battery cables and either disconnect or open the control circuit breaker for the AC power supply to the battery charger. 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 operation and disconnect/lockout all power sources before commencing any work.

2. Locate the pump and heater breakers inside of the dosing cabinet. A 301-8313 Terminal Block will need to added and replace the existing 301-8312 Terminal Block. Refer to Image 1.2.1.

Image1.2.1

3. Drill a 6.6 mm hole in the dosing cabinet sidewall. Refer to Image 1.2.1 for the dimensions. Remove the paint around the drilled hole to ensure good conductivity. Install and tighten the 389-2139 Ground Cable to the 6.6 mm hole using a 6V-8214 Bolt, 9X-8267 Washer and 5C-2890 Nut. Install the wire end of the 389-2139 Ground Cable into the fourth terminal slot in the 301-8313 Terminal Block.

4. Drill a 6.6 mm hole in the dosing cabinet sidewall. Refer to Image 1.4.1 for the dimensions. Remove the paint around the drilled hole to ensure good conductivity. Install a 146-1815 Ground Cable using a 6V-8214 Bolt and 5P-4115 Washer. Do not tighten as the outside of the dosing cabinet will also have a ground strap in this same hole location. Remove the existing bolt and nut that connect the upper and lower sections of the dosing cabinet. Install and tighten the other end of the 146-1815 Ground Cable using a 6V-2315 Bolt and 5C-2890 Nut.

Image1.4.1

5. Install and tighten a 108-5747 Ground Cable to the outside of the dosing cabinet using a 5C-2890 Nut. This is same hole that was drilled in Step 4. Refer to Image 1.5.1. Remove the existing bolt and nut that connect the upper and lower sections of the dosing cabinet. Attach the other end of the 108-5747 Ground cable using a longer 6V-2315 Bolt. Refer to Image 1.5.2.

Image1.5.1

Image1.5.2

6. On the lower portion of the dosing cabinet outer sidewall, drill an 11 mm hole. Refer to Image 1.6.1 for dimensions. Remove the paint around the drilled hole to ensure good conductivity. Install and tighten the 175-1540 Ground Boss using a 6V-5842 Bolt, two 6V-5839 washers, and 2Y-5829 Nut. Install the 233-0059 Ground Film next to the ground boss.