PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MECHANICAL FOAM RETENTION KIT ON CERTAIN C9 GENERATOR SETS AND C15 GENERATOR SETS (XQ230, XQ300, AND XQ400 GENSETS) Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MECHANICAL FOAM RETENTION KIT ON CERTAIN C9 GENERATOR SETS AND C15 GENERATOR SETS (XQ230, XQ300, AND XQ400 GENSETS)

Usage:

REBE4151-01

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30Jul2008

(Revised 06Nov2008)

U-392

A-319

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MECHANICAL FOAM RETENTION KIT ON CERTAIN C9 GENERATOR SETS AND C15 GENERATOR SETS (XQ230, XQ300, AND XQ400 GENSETS)
7274 7263		PI31538

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31538" 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 "PI31538" 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:

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 30Jul2008 Service Letter. Changes have been made to Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Jan2009	31Jul2009

PROBLEM

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The interior sound foam needs a mechanical retention kit added on certain C9 Generator Sets and C15 Generator Sets. (XQ230, XQ300, and XQ400 Gensets) The interior sound foam liner adhesive can fail on the range of serial numbers.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C9	X3R00100-00918

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*****Group 2*****
C15	X4R00100-00404

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3326882	KIT-MECH FSTNR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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	3326883	KIT-MECH FSTNR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 2

PARTS DISPOSITION

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

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING MECHANICAL FOAM RETENTION KIT ON CERTAIN C9 GENERATOR SETS AND C15 GENERATOR SETS (XQ230, XQ300, AND XQ400 GENSETS)

MODELS INVOLVED - XQ230, XQ300, AND XQ400 GENSETS

Dear Caterpillar Product Owner:

The interior sound foam needs a mechanical retention kit added on the products listed below. The interior sound foam liner adhesive can fail on the range of serial numbers. 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 30Jul2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 30Jul2008 Service Letter

Rework Procedure

Group Number 1

References:
RENR8644 Service Manual
SENR9868 Testing and adjusting
SEBU7911 Operation and Maintenance Manual

1. Isolate Genset before commencing any work on the unit, activate
Emergency stop, open Genset breaker and disconnect battery cables.
Ensure health and safety requirements are adhered to at all times.

2. Add straps (Item 5) as shown on Image 1.1.1 below. Use supplier part number 53D255 in parts kit 332-6882. Use 2 per door, using existing enclosure assembly bolts.

Image1.1.1

3. Remove the panel on the enclosure roof above the silencer. see Image 1.2.1

Image1.2.1

Image1.2.2

4. Install the duct shield consist as detailed in Image 1.3.1.
Assemble to match Image 1.2.1 using the existing enclosure assembly bolts.

Details of enclosure assembly bolts (Image 1.2.2)

5. Use Items 6 and 7 to fasten duct sheild into place (Image 1.3.2)

Image1.3.1

Image1.3.2

Image1.3.3

6. After duct shields are fitted, install the panel on the enclosure roof above the silencer.

7. Clear generator area, reconnect batteries, and release emergency
stop.

8. Run functional No load test on Genset.

Group Number 2

RENR8643 Service Manual
SENR9928 Testing and adjusting
SEBU7910 Operation and Maintenance Manual

1. Isolate Genset before commencing any work on the unit, activate
Emergency stop, open Genset breaker and disconnect battery cables.
Ensure health and safety requirements are adhered to at all times.

2. Add straps (Item 4) as shown on Image 2.1.1 below. Use supplier part number 53D255 in parts kit 332-6883. Use 2 per door, using existing enclosure assembly bolts.

Image2.1.1

3. Remove the panel on the Enclosure roof above the silencer. See Image 2.2.1

Image2.2.1

Image2.2.2

4. Install the duct shield consist as detailed in Image 2.3.1.
Assemble to match Image 2.2.1 using the existing enclosure assembly bolts.

Details of Enclosure assembly bolts (Image 2.2.2)

5. Use Items 5 and 6 to fasten duct sheild into place (Image 2.3.2)