PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL LINES ON CERTAIN C175 GENERATOR SETS, 793F, 793F XQ, 795F AC, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL LINES ON CERTAIN C175 GENERATOR SETS, 793F, 793F XQ, 795F AC, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS

Usage:

REBE7040-05

08Sep2011
(Revised 23Mar2012)


U-377
A-313
D-335
O-328

 

Before/After

  
 Parts stock action needed 

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL LINES ON CERTAIN C175 GENERATOR SETS, 793F, 793F XQ, 795F AC, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS

1252
PS43366
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 "PS43366" 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.

NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7755" as the Group Number, "56" as the Description Code.

NOTE:

Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.

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.

 
NOTE:

This Revised Service Letter replaces the 08Sep2011 (Revised 27Feb2012) Service Letter. Changes have been made to add Parts Stock Action.


TERMINATION DATE

30Sep2013

PROBLEM

The existing fuel line can fail on certain C175 Generator Sets, 793F, 793F XQ, 795F AC, 797F, and 797F XQ Off-Highway Trucks. If the existing fuel line fails it will cause a leak.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
C175-16  WYB00100-00112, 114-118, 124-129, 131, 135-136, 138-454, 456-574, 576-660
*******Group  2*******
793F  SSP00112-00415, 417, 419-420, 452
793F XQ  SND00100-00110
*******Group  3*******
797F  LAJ00141-00287, 289, 292
797F XQ  WSP00100-00101, 105
*******Group  4*******
795F AC  ERM00151-00180, 182-186

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
2 3E4353 WASHER-HARD
2 5G3676 GROMMET
2 6V1820 BOLT
1 6V5686 BOLT-HEX HEAD
2 6V7673 BOLT-HEX HEAD
2 7D1649 WASHER-HARD
2 8T1889 CLIP-2 PIECE
2 8T1890 CLIP-2 PIECE
1 9X8268 WASHER
4 2287091 SEAL-O-RING-ORS
2 3538507 HOSE AS
1 3683006 BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 21% 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*******
2 3E4353 WASHER-HARD
2 5G3676 GROMMET
2 6V1820 BOLT
1 6V5686 BOLT-HEX HEAD
2 6V7673 BOLT-HEX HEAD
2 7D1649 WASHER-HARD
2 8T1889 CLIP-2 PIECE
2 8T1890 CLIP-2 PIECE
1 9X8268 WASHER
4 2287091 SEAL-O-RING-ORS
2 3538506 HOSE AS
1 3683006 BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 3*******
2 3E4353 WASHER-HARD
2 5G3676 GROMMET
2 6V1820 BOLT
1 6V5686 BOLT-HEX HEAD
2 6V7673 BOLT-HEX HEAD
2 7D1649 WASHER-HARD
2 8T1889 CLIP-2 PIECE
2 8T1890 CLIP-2 PIECE
2 9X8268 WASHER
4 2287091 SEAL-O-RING-ORS
2 3538507 HOSE AS
1 3683006 BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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 4*******
2 3E4353 WASHER-HARD
2 5G3676 GROMMET
2 6V1820 BOLT
1 6V5686 BOLT-HEX HEAD
2 6V7673 BOLT-HEX HEAD
2 7D1649 WASHER-HARD
2 8T1889 CLIP-2 PIECE
2 8T1890 CLIP-2 PIECE
2 9X8268 WASHER
4 2287091 SEAL-O-RING-ORS
2 3538507 HOSE AS
1 3683006 BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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

****Parts Stock ****

Rework the following engines in dealer parts stock and/or dealer exchange inventory:

250-7100, 314-2485, 360-1646, 365-9318, 365-9319, 365-9320, and 365-9321 Service Replacement C175-16 Engines with a B7B prefix

288-8962, 300-8722, 314-2486, and 328-1440 Service Replacement C175-16 Engines with a JTL prefix

262-1300, 282-2060, 360-1647, 365-9326, 365-9327, 365-9328, and 365-9329 Service Replacement C175-20 Engines with a LLM prefix

For the B7B prefix, refer to Group Number 2 in the Rework Procedure.
For the JTL prefix, refer to Group Number 4 in the Rework Procedure.
For the LLM prefix, refer to Group Number 3 in the Rework Procedure.

 
 
****Affected Product****
Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

****Parts Stock****

Submit one claim for all engines reworked in dealer parts stock and/or dealer exchange inventory. The parts listed in the Parts Needed will be allowed for each engine that is reworked. 2 hours will be allowed for each engine that is reworked. Include the engine serial numbers and arrangement numbers in the service claim story.

 
 
****Affected Product****
Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-20000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 3.0-hour job for Group 1

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-10000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 3.0-hour job for Group 2

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-10000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 3.0-hour job for Group 3

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-10000 hrs,
0-48 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 3.0-hour job for Group 4



PARTS DISPOSITION

****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.



Rework Procedure


Group Number 1  
 
1. Remove the existing fuel priming lines and support bracket. Refer to Image1.1.1.

NOTE: These parts will not be reused.
Image1.1.1
 
2. Install the bolt and washer that mounts the HP fuel pump to the front housing.

Refer to Image1.2.1. Tighten the bolt to 240 N.m.
Image1.2.1
 
3. Install the new fuel lines and bracket as shown in Image1.3.1 and Image1.3.2.

NOTE: Tighten the bolts that mount the bracket to the pump to 100Nm (74 ft-lbs).

NOTE: Tighten the bolts that mount the fuel lines clips to the bracket to 55Nm (37ft-lbs).
Image1.3.1
Image1.3.2
 
 
Group Number 2   Group Number 4  
 
1. Remove the existing fuel priming lines and support bracket. Refer to Image2.1.1.

NOTE: These parts will not be reused.
Image2.1.1
 
2. Install the bolt and washer that mounts the HP fuel pump to the front housing.

Refer to Image2.2.1. Tighten the bolt to 240 N.m.
Image2.2.1
 
3. Install the new fuel lines as shown in Image2.3.1 and Image2.3.2.

NOTE: Tighten the bolts that mount the bracket to the pump to 100Nm (74
ft-lbs).

NOTE: Tighten the bolts that mount the fuel lines clips to the bracket to
55Nm (37ft-lbs).
Image2.3.1
Image2.3.2
 
 
Group Number 3  
 
1. Remove existing fuel priming lines and support bracket. Refer to Image3.1.1.

NOTE: These parts will not be reused.
Image3.1.1
 
2. Install the bolt and washer that mounts the HP fuel pump to the front housing.

Refer to Image3.2.1. Tighten the bolt to 240 N.m.
Image3.2.1
 
3. Install the new fuel lines as shown in Image3.3.1 and Image3.3.2.

NOTE: Tighten the bolts that mount the bracket to the pump to 100Nm (74 ft-lbs).

NOTE: Tighten the bolts that mount the fuel lines clips to the bracket to 55Nm (37ft-lbs).
Image3.3.1
Image3.3.2
 
 

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