PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUMES DISPOSAL AND FUEL HOSES ON CERTAIN C27 GENERATOR SETS
Usage:
TEBE0013-00
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| 13Sep2013 |
U-427
D-357
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| Safety | PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUMES DISPOSAL AND FUEL HOSES ON CERTAIN C27 GENERATOR SETS |
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| 1317 | PI10942 |
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| NOTE: | This Program must be administered as soon as possible.
When reporting the repair, use "PI10942" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim
Description Code and "T" as the SIMS Description Code.
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PROBLEM
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| The fumes disposal group needs to be reworked on certain C27 Generator Sets. The existing fumes disposal hose can contact the fuel hose, cause failure due to wear, 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 |
| C27 | T4Z00100, 200-249 |
PARTS NEEDED
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Qty |
Part Number | Description |
| 1 | 0S1588 | BOLT |
| 144 | 6V5632 | HOSE |
| 2 | 7X7729 | WASHER-HARD |
| 1 | 8T4133 | NUT |
| 1 | 8T4183 | BOLT-HEX HEAD |
| 1 | 8T4185 | BOLT-HEX HEAD |
| 1 | 8T4186 | BOLT-HEX HEAD |
| 1 | 8T4244 | NUT-HEX |
| 1 | 8T4983 | CLAMP-BAND |
| 2 | 1732090 | SPACER |
| 1 | 4245877 | BRACKET AS |
| 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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| WARNING: Injury can occur to personnel if the rework is done improperly. 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 energization or start up of the generator set. Failure to follow these warnings could result in injury to personnel during service. Areas of improvement need to be addressed in order to prevent possible failure of the fuel hose. These include rework of the fumes disposal and fuel hose routing and support. 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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| NOTE: This is a 1.0-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 SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUMES DISPOSAL AND FUEL LINES ON CERTAIN C27 GENERATOR SETS MODELS INVOLVED - C27 Dear Cat Product Owner: The fumes disposal group needs to be reworked on certain C27 Generator Sets. The existing fumes disposal hose can contact the fuel hose, cause failure due to wear, 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 13Sep2013 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 13Sep2013 Service Letter |
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| C27 Field Rework Instructions Presently the fuel hose can come in contact with the fumes disposal hose as shown in Image 1.1.1. |
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| Image1.1.1 |
| Remove the hardware to the fuel hose bracket shown in Image 1.2.1. The 1293172 stud bolt, 2 8T-4896 washers, and 6V8801 nut will not be reused. Keep the 2 9X-6458 washer, and the 0S-1588 bolt for reuse. Leave the bracket attached and the clip attached to the fumes disposal hose. |
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| Image1.2.1 |
| Remove the 3522174 bracket and mounting hardware shown in Image1.3.1. The bracket will not be reused. Keep 2 0L-1143 bolts and 2 8M-9124 washers required for reuse. |
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| Image1.3.1 |
| Refer to Image 1.4.1 1) Beginning with the 424-5877 bracket use 2 0L-1143 bolts and 2 8M-9124 washers to secure it in place. 2) Install 2 9X-6458 washer, 2 0S-1588 bolt to secure the fuel bracket to the lines. 3) Install a 8T4185 bolt, 2 7X7729 washers, a 8T4133 nut, and a 173-2090 spacer to attach the clip around the fumes disposal hose to the top of the bracket. Parts Required 1 424-5877 BRACKET 2 0L-1143 BOLT 2 8M-9124 WASHER 2 9X-6458 WASHER 2 0S-1588 BOLT 1 8T-4185 BOLT 2 7X-7729 WASHER 1 8T-4133 NUT 1 173-2090 SPACER |
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| Image1.4.1 |
| Remove the hardware shown in Image 1.5.1. The 8T-4136 bolt will not be reused. Retain the 8T-4133 nut and 2 8T-4121 washers. Leave the clip attached to fumes disposal hose. |
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| Image1.5.1 |
| Install the clip to the front of the engine using the required hardware. Parts Required 1 8T-4133 NUT 1 173-2090 SPACER 2 8T-4121 WASHER 1 8T-4186 BOLT |
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| Image1.6.1 |
| Replace the 8T-6703 clamp with a 8T-4983 clamp as shown in Image 1.7.1. Parts Required 1 8T-4983 CLAMP |
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| Image1.7.1 |
| Remove the 8T-8919 bolt and 6V-8801 nut from the Y-connector and install a 8T-4183 bolt and a 8T-4244 nut as shown in Image 1.8.1 Parts Required 1 8T-4183 BOLT 1 8T-4244 NUT |
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| Image1.8.1 |
| Loosen 4 8T-4983 band clamps and remove both 5P-1253 hoses connected to the fumes disposal filters and the Y connector. Cut the 6V-5632 hose to the lengths 412 mm +/- 5 mm and 725 mm +/- 5 mm as shown in Image 1.9.1. Place qty 2 8T-4983 clamps around each 6V-5632 hose. Attach one end of the hose to the fumes disposal filter, and the other end to the Y-connector. Properly position each clamp so that they lay on the flat section of the hose and not on the portion over the hose bead. Tighten the clamps. Parts Required 4 8T-4983 CLAMP 114cm 6V-5632 HOSE |
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| Image1.9.1 |
| Verify that there is a minimum clearance of one inch between the fumes disposal hose and the fuel line. Refer to Image 1.10.1. Readjust if necessary. The generator set can now be returned to service. |
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| Image1.10.1 |
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