PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT EXPANSION TANK HOSE, HOSE CONNECTOR, AND CLAMPS ON CERTAIN C2.2, C4.4, AND C6.6 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT EXPANSION TANK HOSE, HOSE CONNECTOR, AND CLAMPS ON CERTAIN C2.2, C4.4, AND C6.6 GENERATOR SETS

Usage:

REBE6299-00

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08Jul2010

U-248

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT EXPANSION TANK HOSE, HOSE CONNECTOR, AND CLAMPS ON CERTAIN C2.2, C4.4, AND C6.6 GENERATOR SETS
1354		PS43113

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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 "PS43113" 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

31Jul2012

PROBLEM

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The existing coolant expansion tank hose, hose connector, and clamps can cause leaks on certain XQ C2.2, C4.4, and C6.6 generator sets. If the existing expansion tank hose, hose connector, and clamps leak it can cause eventual genset low coolant level alarms and cause the generator set to shut down.

AFFECTED PRODUCT

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Model	Identification Number
C2.2	GBE00108-00126, 128-168, 171-174, 181-183, 186, 191, 206-208, 210-212, 214-219, 221-224, 235-236, 238, 240, 243, 252-254, 269, 277, 284-286, 290-293, 304, 312-314, 350-360, 383, 401-412, 414-419, 423-424, 426, 431-433, 435
C4.4	D4D00410, 612-618, 622-792 GLE00301-00302, 700-722, 724-756, 758-764, 766-785
C6.6	MRW00100-00102, 104-199, 201-225

PARTS NEEDED

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Qty	Part Number	Description
1	8C3681	HOSE-BULK ( 3 m - Cut As Required)
1	1025758	END-HOSE
2	1246275	CLAMP-WORM DRIVE
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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Replace the coolant expansion tank hose, hose connector, and clamps.

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%
0-2000 hrs, 0-12 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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The existing hose (1) is green in appearance.

1. Loosen the clamps securing the existing hose (1) to the coolant expansion tank (2) and the radiator connection.

2. Remove the existing hose (1) and clamps from the connectors to the expansion tank and radiator, do not reuse.

Image1.1.1

Image1.1.2

3. Remove the existing hose end connector from the coolant expansion tank (2), do not reuse.

4. Install the new 102-5758 Hose End (4) in the coolant expansion tank (2).

Image1.2.1

5. Place a new 124-6275 Clamp (5) over a free end of the new 8C-3681 Hose (3). Push the free end of the 8C-3681 Hose (3) over the installed 102-5758 Hose End (4) on the coolant expansion tank (2). Tighten the clamp (5) to secure the hose in position.

Image1.3.1

6. Cut the 8C-3681 Hose to the correct length as required for the installation.

7. Place a new 124-6275 Clamp over the remaining free end of the 8C-3681 Hose. Push the end of the hose over the connector at the radiator (not shown). Tighten the new clamp to secure the hose in position.