PRODUCT SUPPORT PROGRAM FOR REWORKING THE CLEAN EMISSIONS MODULE (CEM) MOUNTING BRACKET ON CERTAIN XQ350 RENTAL PACKAGES (C13 GENERATOR SETS) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE CLEAN EMISSIONS MODULE (CEM) MOUNTING BRACKET ON CERTAIN XQ350 RENTAL PACKAGES (C13 GENERATOR SETS)

Usage:

TEBE3818-01

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14Mar2016

(Revised 01Apr2016)

U-132

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Before/After	PRODUCT SUPPORT PROGRAM FOR REWORKING THE CLEAN EMISSIONS MODULE (CEM) MOUNTING BRACKET ON CERTAIN XQ350 RENTAL PACKAGES (C13 GENERATOR SETS)
1273 108D		PS45019

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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 "PS45019" 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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NOTE:	This Revised Service Letter replaces the 14Mar2016 Service Letter. Changes have been made to the Parts Needed, Action Required, and Rework Procedure.

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TERMINATION DATE

31Mar2018

PROBLEM

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The existing Clean Emissions Module (CEM) mounting bracket on certain XQ350 Rental Packages (C13 Generator Sets) may allow excess side-to-side motion during transportation. Since the CEM mounting bracket is mounted to the top of the fuel tank, this excess motion may cause the top of the fuel tank to crack. Additional bracing will need to be added to stabilize the CEM mounting bracket.

AFFECTED PRODUCT

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Model	Identification Number
C13	X3M00100-00199, 300-572

PARTS NEEDED

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Qty	Part Number	Description
8	4L9337	BOLT-HEX HEAD
8	5P1075	WASHER-HARD
1	4952741	KIT-SUPPORT
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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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.

Repair Action Required

Additional bracing will need to be installed to stabilize the CEM mounting bracket. The bracing is mounted to the CEM mounting bracket and canopy wall. The bracing will attach to existing holes in the canopy wall, but holes will need to be drilled in CEM mounting bracket to secure the bracing. Note that 099-3649 Bolts and 5P-1075 Washers included in 495-2741 Kit-Support are not to be used. These are the incorrect size. In place of this hardware, 4L-9337 Bolts and 5P-4116 Washers should be used. Refer to Image1.

If cracking is found on the top surface of the fuel tank, provide a description and picture of the crack to the Global Dealer Solution Network (GDSN) Service Technical support entry. Create the entry, but do not submit to Caterpillar. Instead, include the email address Herzog_William_E@cat.com in the cc field and close the ticket at the dealership.

If cracking is found on the top surface of the fuel tank, weld repair by the tank manufacturer will be required. See contact information below to schedule tank repair.

Bill Herzog
Phone: (770) 233-3940
Email: Herzog_William_E@cat.com

Refer to Special Instruction, REHS1841, "General Welding Procedures". Within this special instruction, refer to the section titled "Welding on Fuel Tanks and Hydraulic Tanks". Pressure testing of the tank and repainting of the welded area will be required after repair.

See Image2 for example of typical tank crack.

Refer to the attached Rework Procedure.

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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%
0-20000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job
Reimbursement for tank repair by the tank manufacturer is covered at cost. Retain a copy of the invoice for outside expenses in the product history folder for audit purposes. This repair should be scheduled and approved through Caterpillar prior to repair as detailed in the Action Required Section. Attach a copy of the invoice in the SIMSi entry.

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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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The CEM support braces should be attached to the canopy wall first, and then to CEM mounting bracket. Existing bolt holes in the canopy are to be used. Note that the CEM mounting bracket is not centered, therefore the support braces are different lengths. Attach CEM support braces to each side of the canopy walls using qty 4 of 4L-9337 Bolts, and qty 4 of 5P-1075 washers per side. Refer to Image1.1.1.

Image1.1.1

Use bolt pattern in CEM support braces to mark the location of bolt holes for the CEM mounting bracket. Note that a quantity of 495-2742 Spacers may be needed to allow proper fit-up. Drill holes per pattern to accommodate M10 bolts. Refer to Image1.2.1

Attach CEM support braces to each side of CEM mounting bracket using qty 2 of 8T-4185 Bolts, qty 4 of 7X-7729 Washers, and qty 2 of 344-5675 Nuts per side. Refer to Image1.2.2

Image1.2.1

Image1.2.2

If cracking is found on the top surface of the fuel tank, weld repair by the tank manufacturer will be required. Also, pressure testing of the tank and re-painting of the welded area will be required after.

See Image1.3.1 for example of a typical crack.

Run package and check for proper operation.