PRODUCT SUPPORT PROGRAM FOR REWORKING CERTAIN FINAL ASSEMBLY PARTS ON CERTAIN XQ35, AND XQ60 RENTAL GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING CERTAIN FINAL ASSEMBLY PARTS ON CERTAIN XQ35, AND XQ60 RENTAL GENERATOR SETS

Usage:

TEBE6147-00

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12Jul2017

U-355

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING CERTAIN FINAL ASSEMBLY PARTS ON CERTAIN XQ35, AND XQ60 RENTAL GENERATOR SETS
1021 1402 1408 7451 1062 1061		PS45539

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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 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 "PS45539" 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.

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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

31Jul2019

PROBLEM

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Certain final assembly parts may lead to possible wiring or performance problems on certain XQ35, and XQ60 Rental Generator Sets. If the existing concerns are not addressed they can lead to possible downtime.

AFFECTED PRODUCT

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Model	Identification Number
XQ35	JK700100, 103-339
XQ60	CF600103-00275

PARTS NEEDED

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Qty	Part Number	Description
10	3S2093	STRAP-CABLE
2	4K6499	GROMMET
3	7Y3282	WASHER
6	8T4200	BOLT-HEX HEAD
6	8T4224	WASHER-HARD
2	1325789	CLIP-LADDER
1	3969017	PLUG AS-CONN
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 30% 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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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%
0-100 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 6.0-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.

Rework Procedure

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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 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.

Reorient the exhaust flap to avoid the enclosure grate.

Image 1.2.1 shows a exhaust flap (rain cap) that interferes with the enclosure grate.

Rotate the exhaust flap so as to clear the enclosure grate. If necessary loosen the exhaust piping to allow for movement of the piping so that the exhaust flap clears the enclosure grate.

Image1.2.1

Ensure exhaust bellows alignment.

Image 1.3.1 depicts a misaligned bellows.

Loosen the associate bellow clamp, and realign the bellows. Then retighten the associated clamp.

Image1.3.1

Reconnect the fuel sender (if needed).

Image 1.4.1 depicts a disconnected fuel sender.

Reconnect the fuel sender is disconnected.

Image1.4.1

Replace missing fasteners on the service panel (as needed).

Image 1.5.1 depicts missing fasteners.

Install 8T-4200 Bolts and 8T-4224 Washers.

Image1.5.1

Update fasteners and washers on customer connection door flap.

Image 1.6.1 depicts a rubber flap used for the customer connection door.
Image 1.6.2 has arrows pointing toward the washers that need to be replaced with new washers.

In order to better secure the rubber flap, use three 7Y-3282 Washers that are larger.

Image1.6.1

Image1.6.2

Ensure wiring from service panel door does not rub against internal circuit breaker.

Image 1.7.1 depicts a green and yellow conductor (drain) that has the chance of coming into contact with the circuit breaker.

To remove the potential conductor snag risk, take the conductor and tie it back into the wiring bundle associated with the service panel door using a 3S-2093 Cable Strap.

Image1.7.1

Ensure rubber boots are in place for the battery and alternator terminals.

Image 1.8.1 depicts rubber boots that need to be adjusted to fit over the terminals.

In order to resolve this place the rubber boots and use 3S-2093 Cable Straps to secure.

Image1.8.1

For XQ35 models, ensure excitation cable rubber boot is in place on the terminal.

Image 1.9.1 depicts the excitation cable boot from not installed over the alternator terminal.

Ensure the boot is placed back over the terminal and secured with a 3S-2093 Cable Strap to reduce movement.

Image1.9.1

Rotate alternator cable on XQ60 charging alternators.

Image 1.10.1 depicts the charging alternator cable coming into contact with a stud.

Rotate the cable as shown in Image 1.10.2 to clear the stud.

Image1.10.1

Image1.10.2

Battery (+) cable may rub and needs to be rerouted on XQ60 models.

The battery positive cable may be found rubbing against the battery hold down bracket as shown in Image 1.11.1.

At a minimum the cable should be routed behind the bracket. Inspect and reorient as needed using Image 1.11.2 as a guide.

Image1.11.1

Image1.11.2

On XQ60 models secure cabling coming off the battery charger.

Image 1.12.1 depicts battery charger cables left dangling.

They should be secured like Image 1.12.2 shows using 132-5789 Ladder Clips and 3S-2093 Cable Straps.

Image1.12.1

Image1.12.2

On XQ60 models, a grommet is needed for wiring passing through the control panel.

Image 1.13.1 depicts conductors passing through the control panel without a grommet.

If this is the case, please use 4K-6499 Rubber Grommet to protect the wires from the control panel cutout.

Image1.13.1

On XQ60 models, the connector for the heater is missing the lock to keep wiring in place.

Image 1.14.1 depicts a connector for the heater that is missing its lock. This would allow for the wires to be pulled free.

Please inspect the associated connector and replace with a 396-9017 Connector if needed.

Image1.14.1

On XQ35 models, the coolant level sensor wires are being strained, need to reduce tension on the conductors.

Image 1.15.1 shows a coolant level sensor that has wires that are strained. Rework the harness to allow for reduced tension on the wires.