PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOW PRESSURE FUEL HOSE TO SECONDARY FUEL FILTER ON CERTAIN C7.1 GENERATOR SETS, 525D, 535D, AND 545D WHEEL SKIDDERS, 815K SOIL COMPACTORS, 924K, 930K, 938K, 950L, 950GC, 950M, 962L, AND 962M WHEEL LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOW PRESSURE FUEL HOSE TO SECONDARY FUEL FILTER ON CERTAIN C7.1 GENERATOR SETS, 525D, 535D, AND 545D WHEEL SKIDDERS, 815K SOIL COMPACTORS, 924K, 930K, 938K, 950L, 950GC, 950M, 962L, AND 962M WHEEL LOADERS

Usage:

TEBE3223-02

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05Aug2015

(Revised 22Dec2015)

U-413

A-295

D-349

O-355

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOW PRESSURE FUEL HOSE TO SECONDARY FUEL FILTER ON CERTAIN C7.1 GENERATOR SETS, 525D, 535D, AND 545D WHEEL SKIDDERS, 815K SOIL COMPACTORS, 924K, 930K, 938K, 950L, 950GC, 950M, 962L, AND 962M WHEEL LOADERS, D5R XL, AND D6K2 TRACK-TYPE TRACTORS
1252 1258 7750 1274 1261		PI32521

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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 as soon as possible. When reporting the repair, use "PI32521" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. Exception: If the repair is done after failure, use "PI32521" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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 05Aug2015 (Revised 05Nov2015) Service Letter. Changes have been made to the Title, Problem, Affected Product, and Owner Notification Letter.

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COMPLETION DATE	TERMINATION DATE
29Feb2016	31Aug2016

PROBLEM

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The low pressure 442-8531 Fuel Lines Group can fail (cut/rupture) at the clamp edges on either end of the hose on certain C7.1 Generator Sets, 525D, 535D, and 545D Wheel Skidders, 815K Soil Compactors 924K, 930K, 938K, 950L, 950GC, 950M, 962L and 962M Wheel Loaders, D5R XL, and D6K2 Track-Type Tractors.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
924K	HJF00456-00459, 462-474, 478, 480-481, 483-484, 486-488, 490-491, 497, 501-532, 534-568, 570-617, 620-624, 629, 647-655, 661, 664-667, 672-675, 677 SNZ00100
930K	EYE00495-00504, 507-519, 523-545, 547-554, 556-559, 561-575, 577-606, 608-619, 621-635, 637-674, 693-695, 697, 700, 703 FRK00130-00131
938K	REP00150 XXT00650-00652, 655, 659, 662, 664-670, 672-675, 677-683, 688-748, 751-754, 756-767, 769-772, 775-783, 786-801, 803-841, 845, 869-875, 880, 884-885

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*****Group 2*****
C7.1	ETG00101-00104, 106-112, 114-122, 124-128, 130-132, 134-138, 140-145, 147-148, 151-153, 155-157, 159-160, 163, 165-189, 192-195, 198-200 G9R00266

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*****Group 3*****
525D	2L500100-00126
535D	3L500100-00101, 103-107, 109-111
545D	4L500101-00123
815K	WCS00100
950 GC	M5K00148, 152, 154-155, 157, 163, 166-167, 172-181, 184-186, 188-192, 194, 196-200, 202-205, 207-221, 223-243, 245-246, 248-261, 263-269, 271-298, 300-301, 303, 305-308, 310-311, 318-323, 325-326, 329-331, 333, 335-338, 340-343, 345, 347-383, 385, 388-408, 411-419, 421-426, 428, 433, 435-445, 447, 449-544, 546-559, 563-573, 585-589, 622-623, 664
950L	LXX00203-00205
950M	ENE00202
962L	SXS00201-00202
962M	LSE00201
D5R XL	R5A00152-00155
D6K 2	MXK00151-00163, 165-172, 175-242, 244-248

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*****Group 4*****
930K	TNY00003-00030

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	4847200	LINES GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 33% 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	4847200	LINES GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 44% 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	4847200	LINES GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 37% 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	4847200	LINES GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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****Parts Stock ****

Remove all 442-8531 Fuel Lines Groups from dealer parts stock.

****Affected Product****

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Before completing this work, please park the machine in a safe area, disconnect battery, fuel shut-off valve, etc. Read, understand, and apply the safety actions in the Operation and Maintenance Manual.

The low pressure 442-8531 Fuel Lines Group must be removed and replaced with new 484-7200 Fuel Lines group. Refer to the attached Rework Procedure.

For additional instructions, refer to the Disassembly and Assembly instructions "Fuel Filter Base - Remove and Install" appropriate for the machine.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 1
Note: This a 1.0 hour job. An additional 2.0 hours is allowed after failure for cleaning fuel spill.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 2
Note: This a 1.0 hour job. An additional 2.0 hours is allowed after failure for cleaning fuel spill.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 3
Note: This a 1.0 hour job. An additional 2.0 hours is allowed after failure for cleaning fuel spill.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 4
Note: This a 1.0 hour job. An additional 2.0 hours is allowed after failure for cleaning fuel spill.

PARTS DISPOSITION

****Parts Stock****

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

****Affected Product****

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

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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOW PRESSURE FUEL HOSE TO SECONDARY FUEL FILTER

MODELS INVOLVED - CERTAIN C7.1 GENERATOR SETS, 525D, 535D, AND 545D WHEEL SKIDDERS, 815K SOIL COMPACTORS, 924K, 930K, 938K, 950L, 950GC, 950M, 962L, AND 962M WHEEL LOADERS, D5R XL, AND D6K2 TRACK-TYPE TRACTORS

Dear Cat Product Owner:

The low pressure 442-8531 Fuel Lines Group needs to be removed and replaced by 484-7200 Fuel Lines Group on the products listed below. The existing secondary filter low pressure 442-8531 Fuel Lines Group can fail at clamp edges on either end of the hose. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 05Aug2015 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to 05Aug2015 Service Letter

Rework Procedure

Secondary filter fuel line rework procedure:

1. GENERAL NOTES

1.1. Unless specified in this rework instruction, build sequence is not critical

1.2. Where tightening torques are not specified they can be found in the Tightening Torques - rework instructions (2.1)

1.3. Before assembly, all parts should be visually inspected to ensure they are free from faults, clean and free from oil and grease.

1.4. The fuel system is designed to operate using 4 Micron-filtered fuel and is very sensitive to particle size. It is therefore imperative to adhere to all cleanliness requirements within these rework instructions, for example re-using dirty caps will have a detrimental effect on product durability.

1.5. Any fuel system component that is removed or exposed should be capped with new, clean caps to prevent dirt ingress, e.g. male connector when the low pressure line is removed.

1.6. Before attempting any work on the fuel system ensure that the engine is cleaned of any dirt that might contaminate the fuel system.

1.7. Check there is adequate clearance around all low pressure lines, and that any clipping is in place and correctly orientated.

1.8. Fuel can be hot after engine running. Care must be taken to ensure hot fuel does not come in contact with exposed skin. Allow engine to cool before undertaking any work.

1.9. When fitting banjo union connections make sure that all sealing washers are present.

1.10. Banjo union sealing washers may only be used once and then must be replaced.

2. NON-STANDARD TIGHTENING TORQUES AND MANDATORY TIGHTENING SEQUENCES

2.1. All Banjo Union connections to 21 +/- 2 Nm

3. COMPONENT ASSEMBLY SEQUENCES

3.1. Remove the existing Transfer Pump to Secondary Fuel Filter Fuel Line (442-8531)

3.2. Replace with new Transfer Pump to Secondary Fuel Filter Fuel Line (484-7200)

3.3. Re-Fit the Clip (442-8569)

4. ALIGNMENT SPECIFICATIONS / TOLERANCES

4.1. Clip between Return To Tank Line and Transfer Fuel Pump to Secondary Filter Line using the existing clip (442-8569) already available in the current engine build.

4.2 Clip between Return To Tank Line and Transfer Fuel Pump to Secondary Filter Line, ensure the clip is correctly orientated with the Open Section facing away from the Filter.

5. Final assembly view

5.1 Check that the line is in place as per Image1.1.1 and Image1.1.2.