PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WARNING ALARM GROUPS ON CERTAIN PS-150C AND PS-360C PNEUMATIC COMPACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WARNING ALARM GROUPS ON CERTAIN PS-150C AND PS-360C PNEUMATIC COMPACTORS

Usage:

REBE6147-01

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09Aug2010

(Revised 23Aug2010)

U-309

A-238

D-264

O-267

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WARNING ALARM GROUPS ON CERTAIN PS-150C AND PS-360C PNEUMATIC COMPACTORS
7402 7406		PI10812

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10812" 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 "PI10812" 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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NOTE:	This Revised Service Letter replaces the 09Aug2010 Service Letter. Changes have been made to the Affected Product and to clarify the Rework Procedure.

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PROBLEM

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The warning alarm groups need to be reworked and/or replaced on certain PS-150C and PS-360C Pneumatic Compactors. The existing alarm groups may not meet Caterpillar spectator sound level specifications which 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*****
PS-150C	FPS00279-01018
PS-360C	PJF00250-00454, 456-548

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*****Group 2*****
PS-150C	FPS00150-00278

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3K5178	GROMMET
1	8T4121	WASHER-HARD
1	8T4133	NUT
1	8T4137	BOLT
1	1070568	BRACKET
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	3K5178	GROMMET
2	7K1181	STRAP-CABLE
5	8T4121	WASHER-HARD
3	8T4133	NUT
1	8T4137	BOLT
2	8T6685	BOLT
1	1070568	BRACKET
1	1325789	CLIP-LADDER
1	2441090	ALARM-BACK UP
1	2733264	BRACKET
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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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

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 1.3-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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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE WARNING ALARM GROUPS ON CERTAIN PS-150C AND PS-360C PNEUMATIC COMPACTORS

MODELS INVOLVED - PS-150C and PS-360C

Dear Caterpillar Product Owner:

The spectator warning horn groups need to be reworked or replaced on the products listed below. The existing warning horn groups can fail to meet the Caterpillar standard for spectator sound levels. Failure to rework or replace the existing warning horn groups 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 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 09Aug2010 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 09Aug2010 Service Letter

Rework Procedure

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For group 1 and group 2 machines:

Note: Dimensions shown in the images referencing a dimension to or from a hole are to be measured from the centerline of the referenced hole.

1) Use a suitable fine tooth hole saw to cut two holes in the rear hood. Place heavy-duty tape on the area where the holes are to be drilled to prevent chipping of the gel coat finish. Drill from the outside of the hood towards the inside of the hood. Refer to image 1.1.1 for proper hole diameter and location for PS-150 machines. Refer to image 1.1.2 for proper hole diameter and location for PS-360 machines.

2) For group 1 machines adjust the switch on the backup alarm to the low setting (97 decibels). To accomplish this, remove the rubber plug located on the backside of the alarm in order to access the switch. Set the toggle switch to the center switch position labeled 97 dab(A).

Image1.1.1

Image1.1.2

3) Remove the four bolts attaching the front cover for the steering column. Use a suitable fine tooth hole saw to cut one hole in the front cover for the steering column. Refer to image 1.2.1 for proper hole diameter and location for PS-150 and for PS-360C machines.

Image1.2.1

4) Refer to image 1.3.1. Disconnect and remove the warning horn from inside the steering column. Use 8T4137 Bolt, 8T4133 Nut, and 8T4121 Washer to attach the horn to the short side of the 1070568 Bracket. Attach the long side of the bracket to the weld boss inside the steering column using 8T4137 Bolt and 8T4121 Washer.
Note: On PS-360C machines with the sliding operator station the warning horn will need to be repositioned on the horn mounting strap. Loosen the nut on the back of the warning horn and rotate the warning horn so that the electrical receptacle is positioned downward. Re-tighten the nut on the back of the horn to 13 ft lbs. (18 Nm). On PS-360C machines with the sliding operators station the clip retaining the large red wire located behind the warning horn will need to be bent slightly rearward. This will allow more clearance for the warning horn. Refer to illustration 1.3.1

5) Make sure other components are not in contact with the warning horn. Test the warning horn to ensure proper function.

6) Reinstall the front cover for the steering column. Install the 3K5178 Grommet in the hole for the front cover of the steering column.

Image1.3.1

For group 2 machines only:

7) Disconnect and remove the existing backup alarm.
8) Reference image 1.4.1. Remove the existing bolts (A) in order to mount the new backup alarm.
9) Adjust the switch on the new backup alarm to the low setting (97 decibels). To accomplish this, remove the rubber plug located on the backside of the alarm in order to access the switch. Set the toggle switch to the center switch position labeled 97 dB(A).
10) Use the existing bolts (A) to attach the 2733264 Bracket to the engine.
11) Use 8T6685 Bolts, 8T4133 Nuts, 8T4121 Washers and 1325789 Clip to attach the new backup alarm to the bracket. The alarm should be mounted with the speaker facing away from the engine and towards the holes in the hood.
12) Connect the electrical harness to the new backup alarm. Secure the harness back to the main portion of harness using 7K1181 Cable Straps. Secure the crankcase breather hose to the 1325789 Clip a using 7K1181 Cable Straps.
13) Test the backup alarm to ensure proper function.