MODULE AR-CLEAN EMISSIONS 4900337 - Caterpillar

This is a 1.0-hour job for Group 1
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 1.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GROUND (EARTH) TERMINAL BRACKET
MODELS INVOLVED - Certain 3406C, 3456, C15, and C18 Generator Sets equipped with LC6 Generators
Dear Caterpillar Product Owner:
The ground terminal bracket needs to be replaced on certain 3406C, 3456, C15, and C18 packages equipped with LC6 generators covered in the program. The existing ground connection in the generator may not make a reliable connection between the ground screw and the generator body due to the ground bracket being painted. This may cause an unreliable ground path. If a fault occurs it may result in personal injury or death. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 29Jun2007 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.
Caterpillar Inc.
Identification #(s)
Attached to 29Jun2007 Service Letter
Rework Procedure
Tools required:
Torque wrench (up to 35Nm) with 13mm and 17mm sockets
Hand wrench 10mm
Hand wrench 13mm
Hand wrench 17mm
Instructions
1.1. Check the Generator model is a LC6.
2.1. Isolate Genset before commencing any work on the unit, activate emergency stop, open Genset breaker, and disconnect battery cables. Ensure health and safety requirements are adhered to at all times.
3.1 Remove one side panel from the generator terminal box.
4.1 Remove the original earth bracket
4.1.1 Remove the ground terminal M12 bolt and associated hardware (washer, nut, etc).
4.1.2 Remove existing cables from the earth terminal.
4.1.3 Remove the thread-forming M8 bolt that holds the bracket to the generator barrel.
5.1 Install the new Bracket 307-6560.
5.1.1 Fit the new Bracket 307-6560 to the generator barrel using the thread-forming M8 screw previously removed. Ensure that the screws are tightened to a torque of: 17 lb.ft +/-1.7 lb.ft (23Nm +/-2.3 Nm) See Image 1.1.1.
Note: Thread-forming screw part number 8T-4000 can be used as a replacement for the M8 bolt.
5.1.2 Using the removed M12 bolt and associated hardware, refit the star-washer and screw into the hole in the terminal box and through the bracket hole. See Image 1.1.2.
Note: Ensure that the star-washer is fitted directly onto the surface of the terminal box.
Image1.1.1
Image1.1.2
6.1 Secure the ground cables using the previously removed associated hardware. Image 1.2.1 Use either:
a. A flanged nut, or
b. A plain nut and washer
Ensure that the bolts are tightened to a torque of:
25.8 lb.ft +/-2.6 lb.ft (35Nm +/-3.5 Nm)
Image1.2.1
7.1. Refit the side panel to the generator terminal box.
8.1. Clear generator area, reconnect batteries, and release emergency stop and clear emergency stop fault code.
9.1. Run functional No load test on Generator set.