PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUMES DISPOSAL AND FUEL HOSES ON CERTAIN PMC27 RENTAL GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUMES DISPOSAL AND FUEL HOSES ON CERTAIN PMC27 RENTAL GENERATOR SETS

Usage:

TEBE0028-00

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13Sep2013

U-428

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUMES DISPOSAL AND FUEL HOSES ON CERTAIN PMC27 RENTAL GENERATOR SETS
1317		PI10943

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10943" 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 "PI10943" 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 fumes disposal group needs to be reworked on certain PMC27 Rental 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
*****Group 1*****
PMC27	N1B00100, 115-135

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*****Group 2*****
PMC27	N1B00101-00105, 107-114

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	0S1588	BOLT
4	5P1075	WASHER-HARD
1	5P1076	WASHER-HARD
2	5P2369	CLIP
1	8T4139	BOLT-HEX HEAD
1	4240142	BRACKET AS
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.
*****Group 2*****
1	0S1588	BOLT
1	4L6454	BOLT
4	5P1075	WASHER-HARD
1	5P1076	WASHER-HARD
2	5P2369	CLIP
1	8T4139	BOLT-HEX HEAD
2	1982970	LOCKNUT
1	4240142	BRACKET AS
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 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.

Areas of improvement need to be addressed in order to prevent possible failure of the fuel hose. These include rework of the fumes disposal hose and fuel hose routing and support.

Rework Procedures are provided for Group 1 and Group 2. The power modules in Group 1 include an additional bracket as shown in Image 1.

Refer to the attached Rework Procedure to determine the proper tools and equipment required to safely perform the rework.

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Image1

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 1.0-hour job for Group 1

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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 1.0-hour job for Group 2

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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 HOSES ON CERTAIN PMC27 RENTAL GENERATOR SETS

MODELS INVOLVED - PMC27

Dear Cat Product Owner:

The fumes disposal group needs to be reworked on the products listed below. 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

Rework Procedure

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Group Number 1

Presently an interim bracket has been installed on certain PMC27 Rental Generator Sets to prevent interference between the fuel hose and fumes disposal hoses as shown in Image 1.1.1. This bracket will be replaced.

Image1.1.1

1) Remove the hardware to the fuel hose bracket and clips holding the fumes disposal hoses shown in Image 1.2.1. The 1293172 stud bolt, and 2 8T-4896 washers will not be reused. Keep the 2 9X-6458 washers, 0S-1588 bolt, 2 4L-6454 bolts, and 2 198-2970 lock nuts for reuse. Leave the clips around the fumes disposal hose.

2) Remove both brackets, and the mounting hardware shown in Image 1.3.1. The brackets will not be reused. Keep 2 0L-1143 bolts and 2 8M-9124 washers for reuse.

Image1.2.1

Refer to Image 1.3.1
1)Beginning with the 424-5877 bracket use 2 OL-1143 bolts and 2 8M-9124 washers to secure it in place.
2)Install 2 9X-6458 washers, 2 OS-1588 bolts to secure the fuel bracket to the 424-5877 bracket.
3)Reuse a 4L-6454 bolt and install. Install a 1982970 lock nut, and 2 5P-1075 washers to attach the clips around the fumes disposal hoses to the top of the bracket.

New Parts Required
1 424-5877 BRACKET
1 0S-1588 BOLT
2 5P-1075 WASHER

Reuse
2 OL-1143 BOLT
2 8M-9124 WASHER
2 9X-6458 WASHER
1 0S-1588 BOLT
1 4L-6454 BOLT
1 198-2970 LOCK NUT

Image1.3.1

Refer to Image 1.4.1
Remove the tie strap holding the fumes disposal hoses together.
1)Install the 424-0142 bracket to the exhaust support with a 8T-4139 bolt and a 5P-1076 washer
2)Install a 5P-2369 clip around each of the fumes disposal hoses. Install 2 5P-1075 washers, a 198-2920 locknut and a 4L-6454 bolt to attach the hoses to the bottom of the 424-0142 bracket.

New Parts Required
1 424-0142 BRACKET
1 8T-4139 BOLT
1 5P-1076 WASHER
2 5P-2369 CLIP
2 5P-1075 WASHER

Reuse
1 198-2920 LOCK NUT
1 4L-6454 BOLT

Image1.4.1

Inspect the hose clamp that attaches the fumes disposal hose to the breather shown in Image 1.5.1. If necessary rotate the hose clamp 180 degrees to so that the tensioner is on the bottom to eliminate potential interference with the hose.

Image1.5.1

Verify that there is clearance between the fumes disposal hose and the fuel line. Readjust the hoses if necessary. The Rental Generator Set can now be returned to service.

Group Number 2

Presently the fuel hose can come in contact with the fumes disposal hose as shown in Image 2.1.1

Image2.1.1

Remove the hardware to the fuel hose bracket and clips holding the fumes disposal hoses shown in Image 1.2.1. The 1293172 stud bolt, 2 8T-4896 washers, 9N-1394 bracket,and 6V-8801 nut will not be reused. Keep 2 9X-6458 washers, the 0S-1588 bolt, and the 4L-6454 bolt for reuse. Leave the clips around the fumes disposal hose.

Image2.2.1

Remove the 3522174 bracket and mounting hardware shown in Image 2.3.1. The bracket will not be reused. Keep 2 0L-1143 bolts and 2 8M-9124 washers for reuse.

Image2.3.1

Refer to Image 2.4.1
1)Beginning with the 424-5877 bracket use 2 OL-1143 bolts and 2 8M-9124 washers to secure it in place.
2)Install 2 9X-6458 washers, 2 OS-1588 bolts to secure the fuel bracket to the 424-5877 bracket.
3)Reuse the 4L-6454 bolt and install. Install 1982970 lock nut, and 2 5P-1075 washers to attach the clips around the fumes disposal hoses to the top of the bracket.

New Parts Required
1 424-5877 BRACKET
1 0S-1588 BOLT
1 198-2970 LOCK NUT
2 5P-1075 WASHER

Reuse
2 OL-1143 BOLT
2 8M-9124 WASHER
2 9X-6458 WASHER
1 0S-1588 BOLT
1 4L-6454 BOLT

Image2.4.1

Refer to Image 2.5.1
Remove the tie strap holding the fumes disposal hoses together.
1)Install the 424-0142 bracket to the exhaust support with a 8T-4139 bolt and a 5P-1076 washer
2)Install a 5P-2369 clip around each of the fumes disposal hoses. Install 2 5P-1075 washers, a 198-2920 locknut and a 4L-6454 bolt to attach the hoses to the bottom of the 424-0142 bracket.

New Parts Required
1 424-0142 BRACKET
1 8T-4139 BOLT
1 5P-1076 WASHER
2 5P-2369 CLIP
2 5P-1075 WASHER
1 198-2920 LOCK NUT
1 4L-6454 BOLT

Image2.5.1

Inspect the hose clamp that attachs the fumes disposal hose to the breather shown in Image 2.6.1. If necessary rotate the hose clamp 180 degrees to so that the tensioner is on the bottom to eliminate potential interference with the hose.

Image2.6.1

Verify that there is clearance between the fumes disposal hose and the fuel line. Readjust the hoses if necessary. The Rental Generator Set can now be returned to service.