PRODUCT SUPPORT PROGRAM FOR INSTALLING FUEL LINES ON CERTAIN C1.5 AND C2.2 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING FUEL LINES ON CERTAIN C1.5 AND C2.2 GENERATOR SETS

Usage:

REBE5242-00

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19Nov2009

B420
D120
H190
N050
N140

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSTALLING FUEL LINES ON CERTAIN C1.5 AND C2.2 GENERATOR SETS
1285 1274		PS42989

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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 "PS42989" 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

31May2010

PROBLEM

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Certain C1.5 and C2.2 Generator sets with the FCUL2 24 hour fuel tank option were shipped with the incorrect fuel lines routing. As a result the fuel pump will not be able to provide fuel to the engine.

AFFECTED PRODUCT

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Model	Identification Number
C1.5	GBD00204-00205
C2.2	GBE00169-00170, 220, 228-229, 231-234, 244-247, 271, 281, 288, 294

PARTS NEEDED

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Qty	Part Number	Description
3	0960061	STRAP-CABLE
200	1586067	HOSE
2	2620489	CLAMP-WORM DRIVE
2	2620490	CLAMP-WORM DRIVE
200	2630768	HOSE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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Replace the existing fuel lines with properly routed fuel lines of the correct length.

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%
0-100 hrs	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 appropriate service manual as necessary.

1. Isolate Genset before commencing any work on the unit, open Genset
breaker, activate Emergency Stop, disconnect the auxiliary power
supply for battery charger and heaters, and disconnect 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. Turn the fuel supply to the OFF position. Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel system component that will be disconnected. Fit a suitable cover over disconnected fuel system component. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

3. Loosen the 262-0489 (1) and 262-0490 (2) Hose Clamps, from the coupling on the rail from the Engine for the return, and at the priming pump for the supply. Disconnect the 263-0768 (3) and 158-6067 (4) Hoses. Refer to Image 1.1.1. and Image 1.1.2.

Image1.1.1

Image1.1.2

4. Replace the existing 263-0768 (3) and 158-6067 (4) Hoses with 200 cm lengths (78.74 in) of new hose of the same part number. Use new 262-0489 (1) and 262-0490 (2) Hose Clamps to install the hoses on the Engine for the return and at the priming pump for the supply.

5. Route hoses through the holes in the rails Image 1.2.1

Image1.2.1

6. Secure the fuel lines using 096-0061 (5) Cable Straps. Connect fuel lines to the supply and return stand pipes on the sub fuel base using the 262-0489 (1) and 262-0490 (2) Hose Clamps. Image 1.3.1.

Image1.3.1

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

8. Turn the fuel supply to the ON position, and prime the system.

9. Run functional test on Genset.