PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW OFF ENGINE FUEL LIFT PUMP ASSEMBLY ON CERTAIN C3.3 AND C4.4 CAT BRANDED OLYMPIAN GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW OFF ENGINE FUEL LIFT PUMP ASSEMBLY ON CERTAIN C3.3 AND C4.4 CAT BRANDED OLYMPIAN GENSETS

Usage:

REBE6540-01

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19Jan2011

(Revised 07Apr2011)

U-25

D-126

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW OFF ENGINE FUEL LIFT PUMP ASSEMBLY ON CERTAIN C3.3 AND C4.4 CAT BRANDED OLYMPIAN GENSETS
1258 1261		PS43223

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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 "PS43223" 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 19th January 2011 Service Letter. Changes have been made to serial number populations, where they have been split between 3 & 4 cylinder gensets.

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TERMINATION DATE

31Jan2013

PROBLEM

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The existing fuel lift pump can fail to operate on certain C3.3 and C4.4 CAT branded gensets. If the existing fuel lift pump fails it will cause the engine to stop completely or run poorly due to lack of fuel being supplied to the fuel injection pump.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C4.4	GLE00301-00302, 700-756, 758-764, 766-805, 807, 1000-1049 N4R00318, 327-329, 331-386, 400-402 N4X00100-00101, 103-108, 110-128, 220-221, 223-227, 232, 255, 257-269, 271, 273, 275, 280-281, 287-298, 300-386, 388-464, 466-479

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*****Group 2*****
C3.3	N3X00105, 226, 235-246, 249-252, 264-317, 319-377 X3B00101

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	6I0254	BOLT
3	6I0291	NUT
1	3504324	KIT-CONVERSION - 4 Cylinder Kit
1	3696785	STUD
3	3697894	CLIP
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 2*****
2	6I0254	BOLT
2	6I0291	NUT
1	3504325	KIT-CONVERSION - 3 Cylinder Kit
1	3696785	STUD
3	3697894	CLIP
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

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Remove the exisiting 299-9267 or 299-9265 Electronic Fuel Pump Module and install a new 350-4324 or 350-4325 Fuel Pump Group.

Refer to the attached Rework Procedure for details.

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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%
*****Group 1*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 1

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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%
*****Group 2*****
0-4000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.0-hour job for Group 2

PARTS DISPOSITION

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

Rework Procedure

350-4324 Conversion Kit Contents: 4 Cylinder Kit

365-3618 Fuel Lift Pump Group
350-5171 Element Assembly
350-4320 Clamp
350-4321 Harness
276-1804 Fuel filter Assembly
287-8098 Mounting Isolator
287-8097 Spacer

350-4325 Conversion Kit Contents: 3 Cylinder kit

365-3618 Fuel Lift Pump Group
350-5172 Element Assembly
350-4320 Clamp
350-4321 Harness
276-1804 Fuel Filter Assembly
287-8098 Mounting Isolator
287-8097 Spacer

Procedure

1. Ensure that the generator set has been safely isolated before starting.

2. Remove the existing 299-9267 or 299-9265 Fuel Filter Housing by removing the three bolts and spacers shown in Image1.1.1, retain the bolts for reuse. (Have a suitably sized container underneath to catch the diesel fuel from the fuel pipes and filters).

Image1.1.1

3. Attach the 350-5171 Element Assembly (4 cyl), or 350-5172 Element Assembly (3 cyl), as shown in Image1.2.1 using the six 287-8098 Mounting Isolators, three 287-8097 Spacers, and the three bolts retained in the previous step. (Please note the new filter assembly does not have an electrical connection). Reconnect the fuel pipes to same locations they were removed from on the old filter assembly.

Image1.2.1

4. Mount the 276-1804 Small Fuel/water Separator using one 369-6785 Stud and 6I-0291 Nut as shown in Image1.3.1. Connect the fuel line from the 356-3618 Fuel Pump to the outlet of the 276-1804 Fuel/water Separator and tighten the 369-7894 Hose Clamp, ensuring you do not over tighten and damage the water separator connection. Then connect the fuel supply hose from the fuel tank to the 279-1804 Fuel/water Separator and tighten the 369-7894 Hose Clamp, again ensuring you do not over tighten the clamp.

Image1.3.1

5. Mount the fuel pump to the base-frame of the generator as shown below in Image1.4.1 with the two 350-4320 Clamps, 6I-0254 Bolts, and two 6I-0291 Nuts. Two holes will need to be drilled in the gen set base frame for attaching the 356-3618 Fuel Pump. NOTE: Image1.4.1 shows a single point lifting arrangement, depending on the configuration of your generator set this might not be fitted, the holes will already have been pre-drilled in the base-frame to allow mounting the fuel pump and secure to the frame. Connect the 35-4320 Harness from the 356-3618 Fuel Pump to the supply plug that was connected to the 299-9267 or 299-9265 old style EFPM, no extension will be required.

Image1.4.1

6. Connect the outlet of the 356-3618 Pump to the 350-5171 or 350-5172 Fuel Pump Filter supply hose connection as shown in Image1.5.1.

Image1.5.1

7. Check all fuel connections are tight then reconnect the generator battery.

8. Carry out the fuel priming procedure as shown in the Operator Maintenance Manual.