PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR FILTER ASSEMBLY ON CERTAIN C2.2 GENERATING SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR FILTER ASSEMBLY ON CERTAIN C2.2 GENERATING SETS

Usage:

REBE6587-00

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17Jan2011

U-22

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE AIR FILTER ASSEMBLY ON CERTAIN C2.2 GENERATING SETS
1054 1051		PS51971

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51971" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

31Jan2012

PROBLEM

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The existing air filter assembly on certain C2.2 Generating sets is difficult to service due to restricted access. The restricted access results in the unnecessary dismantling of the assembly to perform service to the air filter element.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C2.2	GBE00175-00179, 192-200, 202-205, 226-227, 256-267, 270, 273, 283, 302, 305-311, 315, 317, 319, 321, 324, 328-330, 332, 342-344, 361, 363-365, 386, 389, 393, 397-398, 400, 420-421, 452-454, 457-459, 465-468, 472, 474-475, 477, 480, 487-488, 493-494, 497-499, 504-506, 508, 510, 530, 536, 539-541, 545-546, 556-557, 560-561, 564, 566, 573, 576, 580-581, 586

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*****Group 2*****
C2.2	GBE00187-00190, 241-242, 248-249, 255, 268, 274, 278-280, 297-300, 322, 333, 335-338, 369, 371-373, 375, 379, 392, 434, 440, 456, 460-461, 495, 575

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3602563	BRACKET
1	3602564	HOSE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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*****
1	2631285	FILTER AS.
1	3602563	BRACKET
1	3602564	HOSE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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Install a new bracket and hose to relocate the air filter and improve service access to the air filter element.

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%
*****Group 1*****
0-1000 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*****
0-1000 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

Group Number 1

1. Isolate the generator set before commencing any work on the unit, open the generator set breaker, activate the emergency stop, disconnect the auxiliary power supply for the battery charger and heaters, and disconnect the 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. Lock out generator before commencing any type of work.

2. Remove the three clamps (1) securing the air filter hose, and the hose assembly (2) from the engine as illustrated in Image1.2.1. Retain the clamps for later use. Do not reuse the hose assembly.

Image1.2.1

3. Unscrew the two M8 bolts (1) securing the air filter assembly (2) to the air filter bracket as illustrated in Image1.3.1. Remove the air filter and retain along with all bolts, washers, and nuts.

Image1.3.1

4. Remove the air filter bracket (1) shown in Image1.4.1 by unscrewing the two M8 bolts (2) securing it to the engine block. Retain the two bolts, washers, and spacers for later use. Do not reuse the bracket.

Image1.4.1

5. Secure the 360-2563 Bracket (1) to the engine as illustrated in Image1.5.1 using the two M8 bolts, spacers, and washers (2) removed in step 4.

Image1.5.1

6. Fit the air filter assembly (1) to the bracket using two M8 bolts, washers, and nuts (2) as illustrated in Image1.6.1. Use the parts removed in step 3.

Image1.6.1

7. BEFORE COMPLETING THIS STEP, ENSURE THAT THE HOSE AND AIR FILTER ASSEMBLY ARE FREE OF DEBRIS. Use the three clamps (1) removed in step 1 to fit and secure the air filter hose (2) to the engine and air filter assembly as illustrated in Image1.7.1.

Image1.7.1

Group Number 2

2. Remove the three clamps (1) securing the air filter hose, and the hose assembly (2) from the engine as illustrated in Image2.2.1. Retain the clamps for later use. Do not reuse the hose assembly.

Image2.2.1

3. Unscrew the two M8 bolts (1) securing the air filter assembly (2) to the air filter bracket as illustrated in Image2.3.1. Retain the two bolts, washers, and nuts. Do not reuse the air filter.

Image2.3.1

4. Remove the air filter bracket (1) shown in Image2.4.1 by unscrewing the two M8 bolts (2) securing it to the engine block. Retain the two bolts, spacers, and washers for later use. Do not reuse the bracket.

Image2.4.1

5. Secure the 360-2563 Bracket (1) to the engine as illustrated in Image2.5.1 using the two M8 bolts, spacers, and washers (2) removed in step 4.

Image2.5.1

6. Fit the 263-1285 Filter Assembly (1) to the 360-2563 Bracket using two M8 bolts, washers, and nuts (2) as illustrated in Image2.6.1. Use the parts removed in step 3.

Image2.6.1

7. BEFORE COMPLETING THIS STEP, ENSURE THAT THE HOSE AND AIR FILTER ASSEMBLY ARE FREE OF DEBRIS. Use the three clamps (1) removed in step 1 to fit and secure the new 360-2564 Hose (2) to the engine and air filter assembly as illustrated in Image2.7.1.