PRODUCT SUPPORT PROGRAM FOR REWORKING THE DOOR LIFT GROUP AND AIR FILTER SUPPORT BRACKET ON CERTAIN C4.4 (D60) GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE DOOR LIFT GROUP AND AIR FILTER SUPPORT BRACKET ON CERTAIN C4.4 (D60) GENERATOR SETS

Usage:

TEBE3888-00

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04Jan2016

U-8

A-7

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REWORKING THE DOOR LIFT GROUP AND AIR FILTER SUPPORT BRACKET ON CERTAIN C4.4 (D60) GENERATOR SETS
7170 1051		PS53113

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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 "PS53113" 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

31Jan2018

PROBLEM

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The existing door lift group and air filter support bracket can interfere with serviceability on certain C4.4 (D60) Generator Sets.

AFFECTED PRODUCT

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Model	Identification Number
C4.4	MZT00101-00102, 104-105, 116, 121, 128, 132-133

PARTS NEEDED

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Qty	Part Number	Description
4	5P4116	WASHER-HARD
2	8T4121	WASHER-HARD
2	8T4137	BOLT-HEX HEAD
4	8T4189	BOLT-HEX HEAD
8	8T4224	WASHER-HARD
2	8T7547	BOLT-HEX HEAD
4	1424901	SCREW-BUTTON HD
4	2086176	STUD-BALL
6	3445674	NUT-HEX
1	4950160	ANGLE-LH
1	4950161	ANGLE-RH
2	4950162	BRACKET AS
1	4954823	BRACKET
2	4959214	SPRING AS-GAS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 20% 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%
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-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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Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction, on the product, and in this product's Operation and Maintenance Manual (OMM). If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication, the warnings that are on the product, and the warnings that are in the OMM are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, the user must ensure that it is safe for the user and for other people to use.

The user should ensure that the product will not be damaged or the product will be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

WARNING: The generator set must be isolated electrically before and while the rework is performed. Follow the proper lockout tag out procedures to protect against the unexpected energizing or startup of the generator. Failure to follow these warnings could result in injury to personnel during service. Attach a "Do Not Operate" warning tag to the machine start switch or the controls before you perform any service to the machine.

Lift Group Rework

1)Remove springs and all hardware securing the components from enclosure and discard.

2)Install Qty 2 of 495-0162 bracket to door using Qty 4 of 142-4901 screw.

3)Install Qty 1 of 495-0160 to left side of enclosure opening. Secure with Qty 2 of 8T-4189 bolt, Qty 4 of 8T-4224 Washer, and Qty 2 of 344-5674 nut.

4)Install Qty 1 of 495-0161 to right side of enclosure opening. Secure with Qty 2 of 8T-4189 bolt, Qty 4 of 8T-4224 Washer, and Qty 2 of 344-5674 nut.

5)Install Qty 1 of 208-6176 stud-ball to each 495-0162 bracket. Secure with Qty 1 of 344-5674 nut.

6)Install Qty 1 of 208-6176 stud-ball to the 495-0160 angle. Secure with Qty 1 of 344-5674 nut.

7)Install Qty 1 of 208-6176 stud-ball to the 495-0161 angle. Secure with Qty 1 of 344-5674 nut.

8)Install Qty 2 of 495-9214 spring to the left and right side using previously installed hardware.

NOTE: Reference images below for assistance with installation.

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

Image1.2.5

Air Filter Mounting Bracket Rework

1)Remove 262-0496 clamp and disconnect 267-1750 hose from housing assembly.

2)Remove Qty 2 of 6V-5218 bolt and Qty 2 of 260-6685 washer securing air filter housing to bracket. Sit air filter housing to the side for reassembly and discard hardware.

3)Remove Qty 4 of 8T-6466 bolt and Qty 4 of 8T4121 washer securing 317-4113 bracket to the engine block.

4)Install 495-4823 bracket to the engine block. Secure using Qty 2 of 8T-4121 washer and Qty 2 of 8T-4137 bolt.

5)Install air filter housing to 495-4823 bracket using Qty 4 of 5P-4116 washer, Qty 2 of 8T-7547 bolt, and Qty 2 of 344-5674 nut-hex.

6)Install 267-1750 hose and secure with 262-0496 clamp.

NOTE: Reference images below for assistance with installation.