PRODUCT SUPPORT PROGRAM FOR REROUTING THE FUEL RETURN LINE ON CERTAIN XQ60 GENERATOR SETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REROUTING THE FUEL RETURN LINE ON CERTAIN XQ60 GENERATOR SETS

Usage:

TEBE6115-00

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15May2017

U-269

A-179

D-211

O-217

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Before/After	PRODUCT SUPPORT PROGRAM FOR REROUTING THE FUEL RETURN LINE ON CERTAIN XQ60 GENERATOR SETS
1021 7554 1280		PS45484

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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 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 "PS45484" 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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TERMINATION DATE

31May2019

PROBLEM

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On certain XQ60 Generator Sets the existing fuel return line may rub against the engine which may damage the fuel line.

AFFECTED PRODUCT

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Model	Identification Number
XQ60	CF600102-00273

PARTS NEEDED

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Qty	Part Number	Description
64	1032529	HOSE-BULK (64 CM)
3	1783620	STRAP-DUAL CLAMP
1	3012722	CONNECTOR-SPL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 30% 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%
0-8000 hrs, 0-12 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 set. 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.

Inspect the unit in question. Image 1.2.1 shows the "wrong bracket orientation" with the return fuel line resting on the bracket. If this is the case with the unit under repair proceed with the directions below.

Image1.2.1

1. Remove the current fuel return line and replace with a longer fuel hose using 64 cm (640 mm) of 103-2529 Bulk Hose. While installing the hose use the 301-2722 Hose Connector. Use the currently installed 6D-4244 Clip to orient the hose away from the rub point shown in Image 1.2.1.

2. After replacing the hose with the correct length hose, install the 178-3620 Dual Strap Clamps.

Reference Image 1.3.1 and Image 1.3.2 for further detail on routing and securing the return fuel hose.