PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL RETURN LINE ON CERTAIN C18 MARINE ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL RETURN LINE ON CERTAIN C18 MARINE ENGINES

Usage:

TEBE5169-01

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12Dec2016

(Revised 19Jun2017)

U-641

A-462

D-538

O-538

TM-11

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL RETURN LINE ON CERTAIN C18 MARINE ENGINES
1274		PS45321

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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 "PS45321" 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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NOTE:	This Revised Service Letter replaces the 12Dec2016 Service Letter. Changes have been made to the Rework Procedure steps and the Service Claim Allowances.

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TERMINATION DATE

31Dec2018

PROBLEM

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The existing 383-3544 Fuel Return Line can fracture near the fuel manifold on certain C18 Marine Engines.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C18	JKX01804-01805, 1814, 1818, 1820-1822, 1824-1825, 1827-1828, 1830, 1832-1835, 1837, 1845, 1849, 1855, 1882-1883, 1896, 1898-1905, 1907-1908, 1910-1912, 1915-1919, 1922, 1925, 1930-1933, 1935-1936, 1940-1941, 1948-1949, 1951, 1954-1956 JLE00102, 104-105, 108-109, 114-120, 123-131, 138-139, 141-142, 144-145, 147, 149, 153-155, 157, 161, 163-164, 167-168, 172, 185-186, 189-191, 194-195, 198-201, 205-206, 210-211, 216-218, 220, 222, 225, 228-230, 232-235, 237-239, 242-244, 247-249, 252, 256-257, 262-267, 274, 278, 281, 284, 288, 292, 297, 304-305, 313-316, 319-321, 325, 327-328, 330-331, 334-335, 345-346, 349-350, 353-354, 358-359, 363-364, 368-369, 372-373, 377-379, 382-383, 389-390, 393, 396, 400, 402-404, 407-414, 417-418, 421-422, 425-426, 429-430, 433-434, 437-438, 441-442, 445-446, 5001-5004, 5006, 5008, 5010-5011, 5015-5016, 5018, 5021-5025, 5028, 5030-5037, 5039-5040, 5051, 5054-5055, 5057, 5059-5060, 5063-5067, 5071, 5081-5082, 5085-5089, 5091-5094, 5101-5110, 5118-5122, 5129-5134, 5140-5145, 5154-5156, 5161-5163, 5165, 5168, 5170-5172, 5175, 5177-5178, 5183, 5185, 5189, 5193-5196, 5200, 5209, 5211-5212, 5215-5217, 5221-5224, 5227-5230, 5233-5234, 5236-5237, 5245, 5249-5252, 5257-5258, 5263-5264, 5266-5268, 5271, 5275, 5279, 5284-5285, 5288-5290, 5293-5297, 5299, 5302-5303, 5306, 5309, 5311-5313, 5320-5321, 5325, 5330-5338, 5340-5342, 5347-5354, 5356-5363, 5365-5366, 5369-5370, 5373-5375, 5377-5378, 5380-5381, 5384, 5388-5394, 5398-5399, 5408-5409, 5411, 5413, 5415, 5418-5422, 5426, 5428-5429, 5432, 5436-5437, 5439, 5441-5442, 5445-5446, 5451-5453, 5455-5456, 5460, 5462-5463, 5465-5466, 5470, 5472, 5476-5478, 5481-5482, 5487-5488, 5491-5496, 5501-5504, 5509-5510, 5514, 5519-5521, 5524, 5526, 5531-5535, 5539, 5541, 5544-5548, 5550, 5554, 5556-5558, 5562, 5564-5566, 5572, 5574, 5577, 5581, 5583-5591, 5601-5602, 5604-5605, 5607, 5610-5613, 5615-5616, 5619, 5622-5623, 5626, 5628

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*******Group 2*******

C18

JKX01819, 1823, 1826, 1829, 1831, 1836, 1838, 1841, 1843, 1847, 1852, 1858, 1868-1869, 1871-1872, 1874-1876, 1880-1881, 1884-1888, 1890-1892, 1895, 1897, 1909, 1913-1914, 1920-1921, 1923, 1927-1928, 1947, 1952-1953, 1957-1959, 1963, 1966, 1973, 1975-1983

JLE00101, 106-107, 110-111, 113, 121-122, 133-137, 140, 143, 146, 148, 150-152, 156, 158-160, 162, 165-166, 169-171, 173, 187-188, 192-193, 196-197, 202-203, 207, 212-215, 219, 221, 223-224, 226, 231, 236, 241, 245, 250-251, 253-255, 258-261, 268-272, 275-277, 279, 282-283, 285-287, 290-291, 294, 299, 302-303, 307-312, 317-318, 322-324, 326, 329, 332-333, 336-340, 343-344, 347-348, 351-352, 355-357, 360-362, 365-367, 370-371, 374-376, 380-381, 384-388, 391-392, 394-395, 397-399, 401, 405-406, 415-416, 419-420, 423-424, 427-428, 431-432, 435-436, 439-440, 443-444, 447-450, 499, 5000, 5005, 5007, 5009, 5012-5014, 5017, 5019-5020, 5026-5027, 5029, 5038, 5041, 5043-5050, 5052-5053, 5056, 5058, 5062, 5068-5070, 5072-5080, 5083-5084, 5090, 5095-5100, 5111-5117, 5123-5128, 5135-5139, 5146-5153, 5157-5160, 5166-5167, 5169, 5173-5174, 5176, 5179, 5182, 5187-5188, 5190-5192, 5197-5199, 5201, 5205-5208, 5210, 5214, 5218-5220, 5225-5226, 5231, 5235, 5238-5239, 5241-5244, 5246-5248, 5253-5256, 5259-5262, 5265, 5269-5270, 5272-5274, 5276-5278, 5280-5283, 5286-5287, 5291-5292, 5298, 5300-5301, 5304-5305, 5307-5308, 5310, 5314-5319, 5322-5324, 5326-5329, 5339, 5343-5346, 5355, 5364, 5367-5368, 5371-5372, 5376, 5379, 5382-5383, 5385-5387, 5395-5397, 5400-5407, 5410, 5412, 5414, 5416-5417, 5424-5425, 5427, 5430-5431, 5433-5435, 5438, 5440, 5443-5444, 5447-5450, 5454, 5457-5459, 5461, 5464, 5467-5469, 5471, 5473-5475, 5480, 5483-5484, 5486, 5489-5490, 5497-5500, 5505-5508, 5511-5513, 5515-5518, 5522-5523, 5525, 5527-5530, 5536-5537, 5540, 5542-5543, 5549, 5551-5553, 5559-5561, 5563, 5567-5568, 5570-5571, 5575-5576, 5579-5580, 5582, 5592-5599, 5603, 5606, 5608-5609, 5614, 5617-5618, 5620-5621, 5624-5625, 5627, 5630-5633

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	7T4469	SPACER
3	8T1887	CLIP
3	8T1888	CLIP
2	9S8752	NUT-FULL
1	9X2085	ADAPTER-ELBOW
2	9X6458	WASHER-HARD
1	2147568	SEAL-O-RING-STOR
2	2287090	SEAL-O-RING-ORFS
2	3294047	STUD-BOLT
3	3537957	GROMMET
1	5163792	LINE AS-HYBRID
1	5196971	LINE AS-HYBRID
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 19% 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*****
2	7T4469	SPACER
3	8T1887	CLIP
3	8T1888	CLIP
2	9S8752	NUT-FULL
1	9X2085	ADAPTER-ELBOW
2	9X6458	WASHER-HARD
1	2147568	SEAL-O-RING-STOR
2	2287090	SEAL-O-RING-ORFS
2	3294047	STUD-BOLT
3	3537957	GROMMET
1	5163792	LINE AS-HYBRID
1	5196971	LINE AS-HYBRID
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 12% 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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1. Remove the rear air cleaner, CCV canister, and CCV hose from valve cover.

2. Remove the clamp holding the elbow on the sea water pump, if necessary for line clearance.

3. Remove the 383-3544 Line. Aftercooler removal is not required. It will be needed to bend or cut the existing line to remove, avoiding the need to remove the aftercooler.

4. Clean the two unused 5/8-18 bolt holes. These may have paint or rust in them. A shortened tap will be required to fit in the space. A square socket and swivel will be needed to drive the tap on the front hole and an adjustable wrench is needed for the rear hole. Refer to Image5 for an image of a modified tap.

5. Remove the fuel temperature sensor and line adapter from the fuel manifold.

6. Install a new 9X-2085 Adapter and re-install the fuel temperature sensor. Use Image1 and 2 for the item location.

7. Install and connect the 516-3792 and 519-6791 Fuel Line. The 228-7090 Seal is used between the lines.

8. Re-install the sea water pump clamp if previously removed.

9. Install 329-4047 Studs and 7T-4469 Spacers into the block. Tighten to a specified torque of 115 +/- 20 N.m (85 +/- 15 lb ft).

10. Install the 353-7957 Grommets, 8T-1887 and 8T-1888 Clips.

11. Tighten the ORFS connections to a specified torque of 65 +/- 10 N.m (48 +/- 7 lb ft), utilizing backup wrenches.

12. Finish by tightening jam nut and attachments, installing air cleaner, CCV canister and CCV hose.

13. Start the engine and check for leaks.

Note: In Image1, Items 21, 42, 55, and 57 are existing parts and are reused.

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Image1

Image2

Image3

Image4

Image5

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*****
0-1000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.8-hour job for Group 1
Note: An additional 1.5 hours is allowed for in hull repairs. Note: An additional 3.0 hours is allowed for cleanup for After Failure only. Reasonable travel time and mileage is allowed. Travel time and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. For other engines that are serviced on the same vessel, reference the other engine serial number(s) in the claim story.

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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*****
0-1000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.8-hour job for Group 2
Note: An additional 3.2 hours is allowed for in hull repairs. Note: An additional 3.0 hours is allowed for cleanup for After Failure only. Reasonable travel time and mileage is allowed. Travel time and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. For other engines that are serviced on the same vessel, reference the other engine serial number(s) in the claim story.