PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTER BASE ON CERTAIN 3456 GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTER BASE ON CERTAIN 3456 GENSETS

Usage:

REBE2173-00

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16Jul2007

D180
D185
D350

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTER BASE ON CERTAIN 3456 GENSETS
1261 1256 1260 1262 1263 1274		PS42460

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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 "PS42460" 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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TERMINATION DATE

31Jul2009

PROBLEM

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The existing fuel filter base can become air locked on certain 3456 powered gensets. If an air lock occurs, the engine could fail to start.

AFFECTED PRODUCT

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Model	Identification Number
3456	C4G00563-00565, 567-572, 575-583, 587-594, 597-604, 606-609, 612-615, 618-621, 623-636, 639-643, 646-693, 695-705, 707-719, 721-722, 724-728, 731-735, 737-740, 778-786, 788-790, 792-803, 805-835, 837-882, 884-923, 926-933, 937-944, 948-949, 952-1064, 1066-1068

PARTS NEEDED

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Qty	Part Number	Description
4	8L2786	SEAL-O-RING
1	1075769	SEAL-O-RING
1	1335673	FILTER AS.-FWS
1	2908866	PUMP GP-F TFR -A (if needed)

ACTION REQUIRED

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Refer to the attached Rework Procedure. NOTE: This rework is to be done on Standby Gensets only.

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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%
0-6000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 1.5-hour job
Note: 1.0 additional hour is allowed if the fuel transfer pump has to be replaced.

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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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Fuel Pump Lift Test

1. Disable automatic start. Disable the electronics so that the engine will not start. Disconnect the engine harness from the Electronic Control Module (ECM).

2. Remove the fuel line from the fuel inlet to the fuel transfer pump.

3. Attach a flexible fuel line to the fuel transfer pump. Put the other end of the flexible fuel line in a container on the ground that is full of fuel. The fuel line needs to have a length of 1 m (3.3 ft) to 3.7 m (12.1 ft). See Image 1.1.1

Note: The fluid lift height (A) must have a minimum of 685 mm (27 inch).

Image1.1.1

4.If equipped, open the purge screw that is on the fuel filter base by three full turns. Do not remove the air purge screw.

5.Crank the engine. Fuel should flow from the purge valve within 15 seconds. If fuel does flow, proceed to Step 6. If fuel does not flow, replace the fuel transfer pump, then proceed to Step 6.

6.Replace the hose assembly from the primary fuel filter to the fuel transfer pump.

7.Close the purge valve if previously opened in Step 4.

Filter Base Re-work

1. Close the fuel tank supply valve.

2. If the primary fuel filter is equipped with a drain valve (1), open the drain valve in order to drain any fuel from the filter case. Close the drain valve (1).

3. Remove the 129-0375 Bowl As (2) and 133-5673 Filter Element (3).

Image1.3.1

4. Disconnect the fuel hoses and fittings (4) from the fuel filter base. Cap the hoses.

5. Remove the plugs (5) from the filter base.

Image1.4.1

6. Remove the 137-4367 Base As from the engine.

7. Drill a 2.38 mm (3/32") hole in the bottom of the 137-4367 Base As into the fuel discharge port (6).

Image1.5.1

8. Thoroughly clean all debris from the filter base, including the ports in the base.

9. Install the 137-4367 Base As on the engine.

10. Replace the 8L-2786 Seal-O-Rings on the 9S-4185 Plugs (7).

11. Install the 9S-4185 Plugs in the filter base (7).

12. Replace the 8L-2786 Seal-O-Rings on the 118-4728 Elbows (8).

13. Install the 118-4728 Elbows in the filter base.

Image1.6.1

14. Connect the hoses to the 118-4728 Elbows.

15. Install a new 133-5673 Filter Element and 129-0375 Bowl As as defined in the Operation and Maintenance Manual SEBU7829.

16. Start the engine and check for leaks. Run the engine for one minute. Stop the engine and check the engine for leaks again.