PRODUCT IMPROVEMENT PROGRAM INSPECTING AND POSSIBLY REWORKING THE LOAD CABLES ON CERTAIN PM1360 POWER MODULES Caterpillar

PRODUCT IMPROVEMENT PROGRAM INSPECTING AND POSSIBLY REWORKING THE LOAD CABLES ON CERTAIN PM1360 POWER MODULES

Usage:

TEBE2301-00

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18Nov2014

U-683

A-507

O-592

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Safety	PRODUCT IMPROVEMENT PROGRAM INSPECTING AND POSSIBLY REWORKING THE LOAD CABLES ON CERTAIN PM1360 POWER MODULES
1408 4459 1404		PI10996

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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 as soon as possible. When reporting the repair, use "PI10996" 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 "PI10996" 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 load cables need to be inspected and possibly reworked on certain PM1360 Power Modules. The existing load cables can be damaged by contacting the bus bars and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
PM3512	TC800100-00102, 104, 131-201

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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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 power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energization or start up of the power module. 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.

An area of improvement needs to be addressed in order to prevent possible failure of the load cables. The procedure details the rerouting of the cable for certain PM1360 Power Modules. Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada
Australia
New Zealand

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 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.

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

SAFETY - PRODUCT IMPROVEMENT PROGRAM INSPECTING AND POSSIBLY REWORKING THE LOAD CABLES ON CERTAIN PM1360 POWER MODULES

MODELS INVOLVED - PM1360

Dear Cat Product Owner:

The load cables need to be inspected and possibly reworked on certain PM1360 Power Modules. The existing load cables can be damaged by contacting the bus bars and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. 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.

You may now search for open Safety Service Letters by entering your product serial number(s). Visit the SAFETY.CAT.COM website and click on the Product Safety page for more information. Please refer the dealer to their Service Letter dated 18Nov2014 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 18Nov2014 Service Letter

Rework Procedure

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Inspect Cable

1. Remove generator control panel cover.
2. Look for contact between the neutral cables with the T3 (W) bus bar as shown in Image 1.1.1
3. Note that the neutral cables should have a .5 inches/13mm clearance around the T3 bus bars. If contact points were found or routing does not meet the minimum clearance requirement, proceed to re-routing the neutral cables.
5. If contact points were not found and the clearance requirements are met reinstall the covers once inspection is complete. The power module is now ready for service.

Image1.1.1

Rerouting the Neutral Cables

1. Remove the cable straps from around the neutral cables. Loosen lug bolts attaching the cables to the bus bar.
Note: cable strap locations vary from one generator to the next.
2. Reroute the neutral cables above the T3 (W) bus bar as shown in Image 1.2.1 while complying with the minimum .5 inches/13mm clearance requirement. Retighten and torque the lug bolts on the bus bar and install new cable straps to hold the cables in place.
3. Reinstall generator panel covers. The power module is now ready for service.