PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL TRANSFER PUMP ON CERTAIN C4.4, C6.6, AND C7.1 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL TRANSFER PUMP ON CERTAIN C4.4, C6.6, AND C7.1 INDUSTRIAL ENGINES

Usage:

TEBE1174-02

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25Jun2014

(Revised 23Sep2014)

U-371

A-264

D-332

O-313

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL TRANSFER PUMP ON CERTAIN C4.4, C6.6, AND C7.1 INDUSTRIAL ENGINES
1256 1261 1274		PS52698

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NOTE:	Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
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 "PS52698" 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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NOTE:	This Revised Service Letter replaces the 25Jun2014 (Revised 12Aug2014) Service Letter. Changes have been made to the Affected Product.

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TERMINATION DATE

30Jun2016

PROBLEM

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The existing Electric Lift Pump (ELP or Fuel Transfer Pump) can fail due to either over voltage spikes or from compromised fuel supply on certain C4.4, C6.6, and C7.1 Industrial Engines.
If the existing Electric Lift Pump (ELP or Fuel Transfer Pump) fails it may result in the engine not stalling due to using fuel from the fuel return line into the secondary filter. The failure of the ELP may also result in blown fuses / tripped circuit breakers and high fuel temperatures. Some C7.1 Litre engines may see a failure to regenerate the DPF.
In some instances the engine may stall or derate.
The replacement ELP will prevent the damage caused by over voltage spikes. The replacement of the air vent connector will prevent fuel from being pulled along the fuel return line into the secondary filter.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C4.4	44800293-00294, 298-333, 336-340, 343-358, 363-365, 367-368, 376-398, 412-415, 439-441, 625-629, 688-691, 738-742, 783-788, 864-873, 882-886, 916-917, 934-938, 950-951, 1025, 1097-1102, 1200-1201, 1206-1207, 1261-1267, 1292-1293, 1501-1503, 1626-1638, 1721-1731, 1743-1754, 1813-1815, 1831, 1835, 2002, 2160-2164, 2168-2170, 2213-2220, 2311-2318, 2396-2403, 2479-2484, 2555-2558, 2563-2566, 2568-2571, 2598-2601, 2608-2611, 2613-2620, 2625-2632, 2674-2681, 2692-2699, 2753-2756, 2764-2767, 2795-2807, 2819-2823, 2828-2835, 2837-2841, 2857-2861, 2922, 3001-3015, 3026-3030, 3045-3047, 3053-3054, 3194-3199, 3207-3212, 3367, 3388-3393, 3401-3408, 3422-3435, 3452-3453, 3472-3492, 3494-3502, 3511-3523, 3527-3534, 3542-3543, 3615, 3637-3645, 3679, 3738-3746, 3784-3791, 3815-3816, 3868, 3905-3906, 3921, 3958, 4046-4047, 4055-4057, 4089-4097, 4159-4161, 4266, 4331, 4392-4395, 4398-4403, 4450-4454, 4476-4481, 4523-4527, 4584-4589, 4599-4612, 4648, 4716-4725, 4755-4770, 4778-4781, 4808-4810, 4861-4876, 4895-4896, 4907, 4915-4920, 4955-4966, 5019-5021, 5149-5152, 5163-5165, 5174, 5188-5192, 5216-5217, 5227-5234, 5239-5246, 5256-5260
C7.1	77000282, 284, 294, 312, 330-331, 355-356, 363-367, 374-382, 392-393, 395, 408, 417-418, 439-441, 443, 445-446, 455-466, 500, 511-512, 515-519, 541-544, 560, 570-571, 589, 653, 662, 664-665, 667, 695, 697-707, 710, 717, 723-726, 754, 760-761, 768-770, 776-778, 787-790, 792-795, 805, 807-811, 827, 833-837, 851-854, 874, 887-891, 895-896, 901-919, 925-928, 931-934, 937-942, 948-949, 952-961, 968-975, 990, 1000-1009, 1011-1012, 1017-1018, 1021-1022, 1025-1026, 1031-1036, 1053, 1098-1101, 1136-1142, 1162, 1177-1178, 1187-1192, 1209-1234, 1245-1246, 1257-1258, 1260-1261, 1268-1272, 1302-1305, 1310-1311, 1314-1319, 1331-1337, 1340-1351, 1353-1365, 1391-1414, 1421, 1432-1439, 1442-1479, 1482-1483, 1493-1496, 1498-1545, 1563-1564, 1567-1609, 1644-1671, 1694-1698, 1716-1725 88100257, 261-263, 265, 276

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*****Group 2*****
C4.4	44800335, 366, 518, 757-765, 1548, 1735, 1773-1781, 1807, 1917-1926, 2404, 5011-5015, 5072-5076
C6.6	66700252
C7.1	77000252-00270, 272-281, 285-293, 299-311, 313, 315-329, 333-354, 357-362, 368-373, 384-391, 396-407, 409-415, 419-438, 442, 444, 447-454, 467-499, 501-510, 513-514, 520-540, 545-559, 561-569, 572-588, 590-652, 654-661, 663, 666, 668-694, 696, 708-709, 711-716, 718-722, 727-753, 755-759, 762-767, 771-775, 779-786, 791, 796-804, 806, 812-826, 828-832, 838-850, 855-873, 875-876, 892-894, 897-900, 920-924, 929-930, 935-936, 950-951, 962-967, 976-989, 991-999, 1010, 1013-1016, 1020, 1023-1024, 1027-1030, 1037, 1046-1050, 1052, 1054-1097, 1102-1135, 1143-1161, 1163-1173, 1176, 1179-1186, 1193-1205, 1207-1208, 1235-1244, 1247-1256, 1259, 1262-1267, 1273-1301, 1306-1309, 1312-1313, 1320-1326, 1328-1330, 1338-1339, 1352, 1367-1376, 1378-1390, 1415-1420, 1422-1431, 1440-1441, 1480-1481, 1484-1492, 1497, 1546-1562, 1565-1566, 1610-1643, 1672-1693, 1699-1715, 1726-1776 88100252-00253, 258, 264, 272, 277, 279-283

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*******Group 3*******

C4.4

44800267-00269, 290-292, 360-362, 515, 517, 519-522, 789, 820-822, 843, 939-949, 961-971, 999-1010, 1012-1024, 1086-1096, 1103-1142, 1144-1145, 1199, 1202-1205, 1218-1223, 1236-1246, 1249-1260, 1288-1291, 1294-1348, 1366-1375, 1377, 1388-1396, 1402-1441, 1477-1494, 1504-1509, 1549-1572, 1574-1600, 1605-1623, 1639, 1695-1703, 1713-1717, 1732-1734, 1736-1740, 1742, 1811-1812, 1816-1830, 1867-1870, 1927-1939, 1944-1949, 1962, 1992-1994, 2005, 2008, 2025, 2060-2067, 2069, 2115-2119, 2138-2140, 2703, 2824-2827, 2973-2976, 3031-3034, 3087-3100, 3103, 3120, 3143-3162, 3174-3193, 3232-3235, 3242-3245, 3301-3311, 3325-3329, 3368-3369, 3399-3400, 3409-3411, 3524-3526, 3547-3552, 3566-3614, 3616-3617, 3633-3636, 3665, 3680-3686, 3751-3757, 3805-3814, 3826-3833, 3850-3867, 3869-3904, 3907-3920, 3952-3957, 3959-4000, 4016-4024, 4040-4045, 4048-4054, 4216-4221, 4391, 5022-5023, 5077-5086, 5139-5148, 5218-5226

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*******Group 4*******

C4.4

44800252-00266, 270-289, 341-342, 369-375, 399-411, 417-437, 442-514, 523-539, 541-624, 630-687, 693-737, 743-755, 767-778, 781-782, 790-819, 823-842, 844-863, 874-881, 887-915, 918-933, 952-960, 973-998, 1026-1085, 1146-1198, 1208-1217, 1224-1226, 1268-1287, 1349-1365, 1378-1387, 1397-1401, 1453-1476, 1510-1547, 1601-1604, 1624-1625, 1640-1691, 1704-1712, 1718-1720, 1755-1772, 1782-1806, 1832-1834, 1836-1866, 1871-1916, 1940-1943, 1952-1961, 1963-1970, 1972-1991, 1995-1997, 1999-2001, 2003-2004, 2009-2020, 2026-2037, 2039-2053, 2055-2059, 2068, 2070-2103, 2105-2114, 2120-2137, 2141-2159, 2165-2167, 2171-2212, 2221-2223, 2225-2271, 2273-2291, 2293-2310, 2319-2395, 2405-2478, 2485-2554, 2559-2562, 2567, 2572-2593, 2595-2597, 2602-2607, 2612, 2621-2624, 2633-2673, 2682-2691, 2700-2702, 2704-2752, 2757-2763, 2768-2794, 2808-2818, 2842-2856, 2862-2921, 2923-2972, 2977-3000, 3016-3025, 3035-3044, 3048-3052, 3055-3086, 3101-3102, 3104-3119, 3121-3132, 3134-3142, 3163-3169, 3171-3173, 3200-3206, 3213-3230, 3236-3240, 3246-3300, 3312-3324, 3330-3366, 3370-3387, 3395-3398, 3412-3421, 3436-3451, 3454-3471, 3503-3510, 3535-3541, 3544-3546, 3553-3565, 3618-3632, 3646-3654, 3657-3664, 3666-3678, 3687-3699, 3703-3737, 3747-3750, 3758-3783, 3792-3804, 3817-3825, 3834-3849, 3922-3951, 4001-4015, 4025-4039, 4058-4070, 4073-4087, 4103-4158, 4162-4209, 4211-4215, 4222-4231, 4233-4264, 4271-4303, 4305-4330, 4333-4378, 4381-4390, 4404-4434, 4436-4449, 4455-4473, 4482-4522, 4528-4583, 4590-4598, 4613-4647, 4649-4715, 4726-4754, 4771-4777, 4782-4807, 4811-4860, 4877-4894, 4897-4906, 4908-4914, 4921-4954, 4968-5001, 5009-5010, 5016-5018, 5026-5071, 5087-5138, 5153-5162, 5170-5173, 5175-5187, 5193-5214, 5247-5255

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*****Group 5*****
C4.4	44800438, 516, 692, 756, 766, 779-780, 972, 1376, 1495-1500, 1573, 1692-1694, 1741, 1808-1810, 1950-1951, 1971, 2006-2007, 2021-2024, 2038, 2054, 2224, 2272, 2292, 3133, 3231, 3241, 3394, 3655-3656, 3700-3702, 4071-4072, 4088, 4098-4102, 4265, 4267-4270, 4332, 4379-4380, 4396-4397, 4435, 4474-4475, 5002-5008, 5024-5025, 5166-5169, 5215, 5235-5238

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3708376	KIT-CLEANLINESS
1	3848512	SCREEN-FUEL
1	4465408	PUMP AS-FUEL XFR
1	4556332	KIT-F CONNECTION
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	3708376	KIT-CLEANLINESS
1	3848512	SCREEN-FUEL
1	4465409	PUMP AS-FUEL XFR
1	4556332	KIT-F CONNECTION
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 3*****
1	3169351	MOUNT-FIR TREE
1	3708376	KIT-CLEANLINESS
1	3848512	SCREEN-FUEL
1	4465393	PUMP GP-F XFR
1	4556332	KIT-F CONNECTION
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 4*****
1	3169351	MOUNT-FIR TREE
1	3708376	KIT-CLEANLINESS
1	3848512	SCREEN-FUEL
1	4465393	PUMP GP-F XFR
1	4556332	KIT-F CONNECTION
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 5*****
1	3169351	MOUNT-FIR TREE
1	3708376	KIT-CLEANLINESS
1	3848512	SCREEN-FUEL
1	4465395	PUMP GP-F XFR
1	4556332	KIT-F CONNECTION
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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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*****
0-4000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-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, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 2

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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 3*****
0-4000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 3

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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 4*****
0-4000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 4

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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 5*****
0-4000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 5

PARTS DISPOSITION

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

Rework Procedure

Group Number 1 Group Number 2

These Electric Lift Pumps (Transfer Pump) are chassis mounted, therefore refer to the relevant Machine Model Disassembly and Assembly Manual for removal and installation instructions of the Electric Lift Pump and Screen-Fuel.

1) Isolate the fuel and electrical supply.
2) Remove and replace the Screen- Fuel. Ensure all open fuel line orifices are capped during the procedure.
3) Remove and replace the Electric Lift Pump (Transfer Pump). Ensure all open fuel line orifices are capped during the procedure.

4) Remove the secondary filter air vent fuel return line. Ensure all fuel pipe orifices are capped off (using capping kit) prior to carrying out the next steps.
5) Remove the secondary filter air vent fuel line connector (this may be a banjo or spigot dependant on machine model). See Image 1.2.1
6) Assemble the replacement secondary filter air vent fuel line connector (banjo or spigot. Ensure new washer/s are used. See Image 1.2.2
7) Tighten the spigot connection to 17+/-2Nm.
8) Tighten the banjo bolt connection to 17+/-2Nm. Ensure the banjo orientation is maintained within the dimension shown in Image 1.2.3 during the tightening operation.
9) Reinstate the fuel and electrical supply.

Image1.2.1

Image1.2.2

Image1.2.3

Group Number 3 Group Number 4 Group Number 5

Paving on engine.
Refer to the relevant Machine model Disassembly and Assembly Manual for removal and installation instructions of the Screen-Fuel.

1) Isolate the fuel and electrical supply.
2) Remove and replace the Screen-Fuel. Ensure all open fuel line orifices are capped during the procedure.

3) Release any clamps securing fuel hose to the spigots of the Electric Lift Pump. Ensure all open fuel line orifices are capped during the procedure.
4) Remove the electrical connector from the Electric Lift Pump.
5) If the starter motor if fitted in front of the Electric Lift Pump then refer to the engine Disassembly and Assembly manual for instructions on removing the Electric Starting Motor. Refer to Image 2.2.1
6) Cut and remove the cable tie that secures the speed sensor wiring harness to the rear of the Electric Lift Pump mounting bracket Refer to Image 2.2.2
7) Undo and remove the Electric Lift Pump mounting bracket bolts (3 off) affixed to the engine. NOTE: Do NOT remove the Electric Lift Pump from the mounting bracket. Refer to Image 2.2.3
8) Remove and replace the Electric Lift Pump.
9) Re-assembly of the replacement Electric Lift Pump is the reverse of the disassembly.
10) Tighten the Electric Lift Pump bracket mounting bolts (3 off M8) to 22+/-5.5 Nm.
11) Re-assembly of the Electric Starting Motor is the reverse of the disassembly. Refer to the engine Disassembly and Assembly manual for assembly instructions.
12) Install the electrical connector to the Electric Fuel Pump ensuring the electrical connector is fully located by carrying out a pullback test.
13) Care must be taken when assembling the cable tie to ensure harness covering is not damaged.

Image2.2.1

Image2.2.2

Image2.2.3

14) Remove the secondary filter air vent fuel return line. Ensure all fuel pipe orifices are capped off (using capping kit) prior to carrying out the next steps.
15) Remove the secondary filter air vent fuel line connector (this may be a banjo or spigot dependant on machine model). See Image 2.3.1
16) Assemble the replacement secondary filter air vent fuel line connector (banjo or spigot. Ensure new washer/s are used. See Image 2.3.2
17) Tighten the spigot connection to 17+/-2Nm.
18) Tighten the banjo bolt connection to 17+/-2Nm. Ensure the banjo orientation is maintained within the dimension shown in Image 2.3.3 during the tightening operation.
19) Reinstate the fuel and electrical supply.