PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE BATTERY CABLES ON CERTAIN C18 (XQ600) GENERATOR SETS Caterpillar


PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE BATTERY CABLES ON CERTAIN C18 (XQ600) GENERATOR SETS

Usage:

TEBE1793-00

21Nov2014


U-690

 

Before/After

  
  

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REWORKING THE BATTERY CABLES ON CERTAIN C18 (XQ600) GENERATOR SETS

7257
PS44569
NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44569" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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.


TERMINATION DATE

30Nov2016

PROBLEM

The existing battery cables on certain C18 (XQ600) Generator Sets may contact the metal framework on the generator base. This rubbing is causing chaffing of the protective shroud on the battery cables, therefore exposing the bare wires and causing an electrical short.

AFFECTED PRODUCT

Model Identification Number
C18  G4C02139, 2144, 2231, 2302, 2327, 2347, 2498, 3863, 3878, 4663, 4674, 4681, 4723, 4743, 4837, 4855-4856, 4859-4862, 4865-4874, 4880-4889, 4891-4895, 4907, 4922-4926

PARTS NEEDED

Qty

Part Number Description
2 0T0772 BOLT
2 1S7251 TERMINAL-RING (After Failure Only)
1 3S6049 TERMINAL AS-BTRY (After Failure Only)
1 3S6050 TERMINAL AS-BTRY (After Failure Only)
2 6D4636 CLIP-LOOP
1 7N5274 COVER-TERMINAL (After Failure Only)
1 8N0869 COVER-TERMINAL (After Failure Only)
1 8N1725 COVER-TERMINAL (After Failure Only)
4 8T5360 WASHER-HARD
1 9G8909 COVER-TERMINAL (After Failure Only)
2 9M5048 LOCKNUT
220 1598049 CABLE-BULK 220 CM (After Failure Only)
220 1598050 CABLE-BULK 220 CM (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

Inspect the battery cables routing to ensure cables do not contact metal framework. If bare wire is exposed proceed with replacing battery cables. Drill holes on fuel hose step and fasten battery cables using P-clips. Ensure sufficient flex is left on the cables to prevent them from being pulled or stretched when generator is in operation. Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-20000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator set. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.
 
1) Inspect current battery cables for contact with metal framework. If contact has occurred inspect for damage to cables. If cables are damaged replace with new. Build new cables with corresponding part numbers below. If cables are free of damage proceed to step 2.

Positive cable (Red)

Part Number Description Qty per battery cable
159-8049 Battery cable (RED) 220 cm
3S-6049 Terminal As Battery 1
8N-1725 Terminal As Cover 1
1S-7251 Terminal Ring 1
8N-0869 Terminal Ring Cover 1

Negaitive cable (Black)

Part Number Description Qty per battery cable
159-8050 Battery cable (BLACK) 220 cm
3S-6050 Terminal As Battery 1
7N-5274 Terminal As Cover 1
1S-7251 Terminal Ring 1
9G-8909 Terminal Ring Cover 1
Image1.2.1
 
2) Remove step fuel hose by removing four bolts.
3) Drill two holes in step fuel hose using dimensions from Image1.3.1.
Image1.3.1
 
4) Reinstall step fuel hose using four bolts and tighten.
5) Install two 6D-4636 Loop Clips to battery cables and secure to step in drilled holes.
Image1.4.1
 
 

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