New Priming Pump for Certain C3.3 and C4.4 Generator Sets{1256, 1258, 1260, 1261} Caterpillar

Generator Set:

C3.3 (S/N: X3B1-1; N3X105-105,226-226,235-246,249-252,264-317,319-377)

C4.4 (S/N: D4D1-1,612-618,622-748,750-750,764-772; GLD1-144,147-171,173-173,176-176,178-178,180-195,197-199,202-204,206-209,211-211,214-272,274-277,279-279,282-294,296-301,303-455,460-460; GLE1-302,700-713,715-722,726-730,732-737,739-756,758-759,770-771; N4R318-318,327-329,331-386,400-402; N4X1-101,103-108,110-128,220-221,223-227,232-232,255-255,257-269,271-271,273-273,275-275,280-281,287-298,300-386,388-464,466-479)

Introduction

There have been a number of isolated instances of issues with 299-9265 Fuel Priming Pump and Primary Filter Gp and 299-9267 Fuel Priming Pump and Primary Filter Gp in certain generator sets. An improved fuel priming pump has been introduced.

Required Parts

For three cylinder engines, 350-4325 Conversion Kit should be installed. The parts that are contained in 350-4325 Conversion Kit are listed in the table 1.

For four cylinder engines, 350-4324 Conversion Kit should be installed. The parts that are contained in 350-4324 Conversion Kit are listed in the table 2.

Removal Procedure

There are two types of fuel priming pump. Type 1 is mounted on the cylinder head. Type 1 is combined with the fuel filter. Type 2 is mounted on the application. Type 2 is not combined with the fuel filter.

Removal Procedure for Type 1

Note: Put identification marks on the fuel hose assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF position.

Show/hide table



Illustration 1	g02140178
Typical example

3. Disconnect the tube assemblies (1) and (5) from the output connections on the fuel filter. Install dust covers onto the connectors for the fuel priming pump.

4. Disconnect the fuel return line from the connector (3). Install a dust cover to the connector (3). Disconnect the harness assembly from the connector.

5. Support the fuel priming pump. Remove the three setscrews and discard the rubber washers (2). Remove the fuel priming pump (4) .

Removal Procedure for Type 2 (If Equipped)

Note: Put identification marks on the fuel hose assemblies for installation purposes. After being disconnected, plug all fuel hose assemblies. This helps prevent fluid loss, and this helps to keep contaminants from entering the system.

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF position.

Show/hide table



Illustration 2	g02145240
Typical example

3. Disconnect the fuel hose assembly (1). Disconnect the fuel hose assembly (3). Install dust covers onto the connectors for the fuel priming pump.

4. Disconnect the harness assembly from the electrical connector on the fuel priming pump.

5. Support the fuel priming pump (2). Remove the two setscrews that are used to secure the "P" clips. Remove the fuel priming pump (2) .

Installation Procedure

There are two types of fuel priming pump. Type 1 is mounted above the starting motor. Type 1 is combined with the fuel filter. Type 2 is mounted on the application. Type 2 is not combined with the fuel filter.

Illustration 3	g02140182
Typical example (1) Remote fuel tank (2) Primary fuel filter/water separator (3) Fuel priming pump (4) Pressure regulator (5) Fuel filter (6) Leak off for the fuel injectors (7) Fuel injection pump (8) Internal fuel tank

Illustration 3 shows the position of the new fuel priming pump assembly within the fuel circuit. The fuel circuit must be followed in order to ensure the correct operation of the fuel system.

Note: The maximum inlet pressure of the new fuel priming pump should not exceed a restriction of 26 kPa (3.77 psi). This includes the restriction due to a primary fuel filter or a water separator.

Note: The maximum length for the fuel lines is 10 m (33 ft) when operating from a remote fuel tank. The minimum internal diameter of the fuel lines should be 12.7 mm (0.50000 inch). The minimum internal diameter of the fuel connections should be 8 mm (0.31496 inch). The generator set should be at the same level as the remote fuel tank when the remote fuel tank is in operation.

Note: The fuel priming pump assembly must be installed to the frame of the generator set. The fuel priming pump should not be mounted on the engine. The fuel priming pump should be mounted as low as possible.

Show/hide table



Illustration 4	g02143953
Typical example

1. Install the new fuel filter assembly (12). Ensure that new isolator mounts and spacers (10) are used. Install three setscrews to the new fuel filter assembly. Tighten the setscrews to a torque of 9 N·m (80 lb in).

   Note: There will not be an electrical connector on the new fuel filter assembly (12) .

2. Install the tube assemblies (9) and (13) to the output connections on the fuel filter.

Show/hide table



Illustration 5	g02145244
Typical example

3. Secure the fuel priming pump (15) to the frame of the generator set with the two rubber coated clips. Ensure that the clips are spaced evenly along the body of the fuel priming pump.

4. Remove the dust covers from the fuel priming pump. Remove the plugs from the fuel hose assemblies. Connect the fuel hose assembly (14) to the input connection of the fuel filter assembly (11) .

5. Connect the fuel hose assembly (16) to the primary fuel filter.

6. Install the lead to the electrical connector. Install the two connections to the fuel priming pump. Use a 5 mm (0.19685 inch) and a 4 mm (0.15748 inch) nut and a washer. Ensure that the 4 mm positive red connection is secure. Ensure that the 5 mm negative black connection is secure. Ensure that the spare material from the lead is secured.

7. Turn the battery disconnect switch to the ON position.

8. Turn the fuel supply to the ON position.

Priming the Fuel System

Priming Procedure for Type 1 Primary Fuel Filter

Fuel Supply from the Base Fuel Tank

Illustration 6	g02145288
Typical example

Note: Do not open the vent screws (B) when the fuel system is being primed.

Show/hide table

NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.

1. Refer to "Generator Set Operation and Maintenance Manual, Section 5.3 Powerwizard" for the correct procedure to prime the generator set.

   Note: Damage to the fuel injection pump, to the battery, and to the starting motor can occur if the starting motor is used excessively to purge the air from the fuel system.

2. In the event of a failure to start the engine, refer to the ""Diagnostic Procedure" " section.

Fuel Supply from a Remote Fuel Tank

1. Ensure that there is fuel in the fuel tank. Ensure that the fuel lines from the remote tank are full of fuel.

2. Switch the fuel supply to the remote tank (if equipped). Prime the fuel system. Refer to ""Fuel Supply from the Base Fuel Tank" ". Follow steps 1 to 2.

Priming Procedure for Type 2 Primary Fuel Filter

Fuel Supply from the Base Fuel Tank

Show/hide table



Illustration 7	g02141076
Typical example

1. Remove handle (1) and lid (2) from the top of the housing (3) .

2. Screw handle (1) into the center tube. The handle (1) should be tightened finger tight.

3. Fill the housing (3) with clean diesel fuel. The diesel fuel should be just above the top of the filter element.

4. Lubricate the gasket for the lid with clean diesel fuel. Lubricate the O-ring for the handle (1) with clean diesel fuel.

5. Replace lid (2). Take care to install the gasket correctly. Tighten the handle (1) finger tight.

6. Ensure that there is fuel in the fuel tank. Turn the fuel priming switch to the PRIME position. Leave fuel priming switch in the PRIME position for 2 minutes.

7. Turn the ignition key to the RUN position.

   Note: Damage to the fuel injection pump, to the battery, and to the starting motor can occur if the starting motor is used excessively to purge the air from the fuel system.

8. In the event of a failure to start the engine, refer to the ""Diagnostic Procedure" " section.

Fuel Supply from a Remote Fuel Tank

1. If the fuel lines from the remote tank are empty, follow ""Fuel Supply from the Base Fuel Tank" ". Follow steps 1 to 6.

2. Repeat the priming procedure. Refer to ""Fuel Supply from the Base Fuel Tank" ". Follow steps 1 to 7.

3. In the event of a failure to start the engine, refer to the ""Diagnostic Procedure" " section.

4. If the fuel lines from the remote tank are full, follow ""Fuel Supply from the Base Fuel Tank" ". Follow steps 1 to 7.

Diagnostic Procedure

If the engine does not start, there may be air in the Pressure Regulator Valve (PRV) return loop hose.

Show/hide table



Illustration 8	g02140653
Typical example

Show/hide table



Illustration 9	g02141538
Typical example

1. Close the PRV return loop hose (1). Use Tooling (A) in order to close the PRV return loop hose (1). A typical example of Tooling (A) is shown in illustration 9.

2. Repeat the priming procedure that is appropriate to the configuration of your fuel system.

3. Release Tooling (A) .

4. Start the engine. Refer to Operation and Maintenance Manual, "Starting the Engine" for the correct procedure. Operate the engine at low idle for a minimum of 5 minutes immediately after air has been removed from the fuel system.

   Note: Running the engine for this period of time will help ensure that the pump is free of air.