PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST ELBOW ASSEMBLY ON CERTAIN XQ350 RENTAL GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST ELBOW ASSEMBLY ON CERTAIN XQ350 RENTAL GENERATOR SETS

Usage:

REBE9407-00

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04Feb2013

U-39

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE EXHAUST ELBOW ASSEMBLY ON CERTAIN XQ350 RENTAL GENERATOR SETS
1061		PS43829

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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 "PS43829" 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

28Feb2014

PROBLEM

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The existing clearance lights and wiring can be damaged on certain XQ350 Rental Generator Sets due to high temperature exhaust gas exposure.

AFFECTED PRODUCT

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Model	Identification Number
C13	X3M00100-00109, 112-118, 120-124, 132, 134-135, 141, 144-146, 148, 164

PARTS NEEDED

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Qty	Part Number	Description
1	48C1821	EXHAUST ELBOW (see Action Required for Ordering)
2	153A	AMBER LED LIGHT (see Action Required for Ordering)
2	15349	PLUG ASSEMBLY (see Action Required for Ordering)
1	3430596/">3430596.	CLAMP-BAND (see Action Required for Ordering)
2	B15018	GROMMET (see Action Required for Ordering)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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Rework of the exhaust assembly needs to be addressed in order to prevent failure of the clearance lights. Repair should be completed before rental if possible.

Before ordering parts inspect the clearance lights (Image 1) and wiring (Image 2). If the lights have been damaged due to excessive exhaust heat exposure order the required quantity of 153A Amber LED Light, 150-18 Grommet, and 153-49 Plug Assembly. The 48C1821 Exhaust Elbow Assembly and the 3430596 Band Clamp will be automatically supplied. All parts request may be made by contacting Shay Leskovisek at ALTORFER Packaging.

Email:sleskovisek@altorfer.com
Fax# 309 282-7546
Phone# 309 697-1234 ext 5119

Please provide the following information upon request for each serial number. Form must ber completed and sent back to Altorfer via email or fax before any parts will be packaged and sent out.

Package Serial Number______________________________________________________
Hour Meter Reading_________________________________________________________
Qty (Max 2 per serial number) of 153A Led Clearance Light__________________
Qty (Max 2 per serial number) of B150-18 Grommet___________________________
Qty (Max 2 per serial number) of 15349 Plug Assembly_______________________
Dealer Name________________________________________________________________
Shipping Address___________________________________________________________
City_______________________________________________________________________
State/Zip Code_____________________________________________________________
Contact Name_______________________________________________________________
Email:_____________________________________________________________________
Phone #:___________________________________________________________________
Fax #:_____________________________________________________________________

WARNING: The power module must be isolated electrically before and while the rework is performed. Follow the proper lockout tagout 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.

WARNING: Injury can occur to personnel if the procedure is done
improperly.

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

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Image1

Image2

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%
0-2500 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.

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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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1. Exhaust Elbow Removal
Loosen exhaust elbow band clamp using 15 mm wrenches.

Image1.1.1

Place a support between the outer wall and upper section of the exhaust elbow. Strike the exhaust elbow with a mallet to disconnect it from the CEM outlet connection.

CAUTION: Prevent the elbow and the support from falling when the elbow is disconnected.

Image1.2.1

Remove the elbow and band clamp from the package. Loosen and remove the rain cap assembly from the elbow using a 1/2 inch wrench. The rain cap will be installed on the replacement exhaust elbow. The elbow and band clamp will not be reused.

Image1.3.1

2. Exhaust Elbow Installation

Install the rain cap on replacement 48C1821 exhaust elbow with the counter weight oriented in the direction shown in Image 1.4.1. Tighten to 25 +/- 6 Nm.
Install a 3430596 Band Clamp on to the elbow at the location shown in the image.

Parts Required
QTY 1 48C1821 EXHAUST ELBOW
QTY 1 3430596 CLAMP-BAND

Image1.4.1

Install the replacement exhaust elbow assembly on to the CEM outlet connection. Confirm that the elbow slip joint is bottomed against the bead on the outlet connection.

Image1.5.1

Align the elbow so that the outlet end is vertical with a minimum of 1 inch clearance between maintained between the elbow and the baffle. While supporting the elbow in position, tighten the band clamp to 55 +/- 8 Nm.

Image1.6.1

3. Clearance Light Replacement
(If Required)
Remove curbside exhaust screen using a 7/16 inch wrench.

Disconnect light wiring at harness connectors and remove any heat damaged parts.
Assemble replacement parts and install light assemblies into each cut out.

NOTE: Light and grommet assemblies snap in or out of the sheet metal cut out from the exterior.

Parts Required
QTY (As Required) 153A AMBER LED LIGHT
QTY (As Required) 15349 PLUG
QTY (As Required) B15018 GROMMET

Image1.8.1

Reconnect the light wiring harness and reinstall exhaust screen. Tighten the bolts to 6 +/- 2 Nm. The Rental Generator Set can now be returned to service.