PRODUCT SUPPORT PROGRAM FOR INSTALLING THE FUEL LINES GROUP ON CERTAIN C4.4 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING THE FUEL LINES GROUP ON CERTAIN C4.4 GENERATOR SETS

Usage:

REBE5656-01

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04Mar2010

(Revised 28May2010)

U-77

A-61

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING THE FUEL LINES GROUP ON CERTAIN C4.4 GENERATOR SETS
1274		PS43046

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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 "PS43046" 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 04Mar2010 Service Letter. Changes have been made to Rework Procedure adding Image 1.1.2. for reference.

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TERMINATION DATE

30Sep2010

PROBLEM

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The fuel lines group needs to be installed on certain C4.4 Generator Sets. The fuel lines group was inadvertently omitted from production.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	D4B00402-00404, 412-415, 431-433, 435, 437, 442-461, 464-465, 470, 472-482, 484, 486, 497, 501-511, 613-620, 622-661, 663-693, 695-701, 802-805, 810-818, 820-838, 840-869, 877-914

PARTS NEEDED

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Qty	Part Number	Description
2	1P4278	CLAMP-HOSE
1	5F5990	CLIP
2	8T0389	LOCKNUT
5	8T4121	WASHER-HARD
1	8T4137	BOLT
2	8T4183	BOLT
2	8T4186	BOLT
2	8T4223	WASHER-HARD
72	2588542	HOSE
3	2609262	ELBOW-90deg
4	2620492	CLAMP-WORM DRIVE
1	2620501	CONNECTOR BSPT T
1	2620536	CONNECTOR BSPT T
95	2818751	HOSE
1	3188064	FILTER GP-FUEL B
1	3256978	BRACKET-LUBE OIL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 14% 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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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%
0-1000 hrs, 0-24 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

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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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Refer to Parts Manual, SEBP5267, 325-6980 Fuel Lines Group for additional details and to Image1.1.1.

1. Isolate the genset before commencing any work on the unit, open the genset breaker, activate the emergency stop, disconnect the auxiliary power supply for the battery charger and heaters, and disconnect the battery cables. Ensure health and safety requirements are adhered to at all times. Also, ensure proper Lock Out-Tag Out procedures are followed at all times while work is being performed on the machine. Lock out generator before commencing any type of work.

2. Mount the 318-8064 Fuel/Water Separator to the 325-6978 Bracket using 2 8T-4186 Bolts, 4 8T-4121 Washers and 2 8T-0389 Locknuts.

3. Mount the fuel/water separator and bracket to the bell housing (1) using 2 8T-4183 Bolts and 2 8T-4223 Washers. See Image1.1.2 for bracket position on units with enclosures.

4. Install both plugs (supplied with fuel/water separator) and both nipples (also supplied) into fuel/water separator housing.

5. Using 53 cm of 281-8751 5/8" Hose, fit 2 260-9262 Connectors to either end and secure with 2 262-0492 Band Clamps. Snap the connectors onto the outlet of the fuel/water separator (2) and the inlet of the injection pump (3).

6. Using 42 cm of 281-8751 5/8" Hose, fit 1 260-9262 Connector to one end and secure with a 262-0492 Band Clamp. Snap the connector onto the inlet of the fuel water separator (4).

7. Screw a 262-0501 Fitting into the fuel supply standpipe on the tank base (5). Using a 262-0492 Band Clamp, fit and secure the other end of 5/8" hose to the fitting.

8. Using 72 cm of 258-8542 3/8" Hose, fit and secure one end to the engine fuel return port (6) using a 1P-4278 Band Clamp. Screw the 262-0536 Hose Connector to the fuel return port on the tank base (7). Fit and secure the remaining end of the 3/8" hose to the connector-hose using a 1P-4278 Band Clamp. Secure the hose to the engine block (8) with an 8T-4137 Bolt, an 8T-0389 Washer and a 5F-5990 Clip.

9. Clear the generator area, reconnect the batteries, and release the emergency stop.

10. Run functional test on the genset.