PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL LINES ON CERTAIN 385C EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL LINES ON CERTAIN 385C EXCAVATORS

Usage:

REBE5263-01

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10Aug2009

(Revised 03Sep2009)

U-289

A-245

D-256

O-263

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL LINES ON CERTAIN 385C EXCAVATORS
1274		PI31683

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31683" 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 "PI31683" 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:

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:

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NOTE:	This Revised Service Letter replaces the 10Aug2009 Service Letter. Changes have been made to Parts Needed and Service Claims Allowance.

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COMPLETION DATE	TERMINATION DATE
28Feb2010	31Aug2010

PROBLEM

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The fuel lines group needs to be updated on certain 385C Excavators. The existing fuel lines can rub and wear causing a fuel leak.

AFFECTED PRODUCT

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Model	Identification Number
385C	JCM00175-00185 KBC00201-00240 KKK00123-00209 MNZ00124-00169
385C FS	EAM00264-00293, 295-296 MMA00245-00275 T2F00181-00188
385C L	EDA00189-00537 KGB00275-00467, 469-472 SBE00168-00459 T2E00291-00341
385C L MH	WAW00211-00226
385C OEM	MSF00101-00102, 104, 106-114
CIPI	0EM01404, 1539, 1839, 1887, 1891

PARTS NEEDED

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Qty	Part Number	Description
1	0S1591	BOLT
1	0S1594	BOLT
2	0S1619	BOLT
1	2L1701	BOLT
2	2R6806	CONNECTOR
3	3E4353	WASHER-HARD
1	5I3190	FITTING
2	5M2894	WASHER-HARD
1	5P8247	WASHER-HARD
1	6V0852	CAP-DUST
1	6V1820	BOLT
1	6V3965	NIPPLE AS
1	6V4248	BOLT
2	7V6571	GROMMET
1	8T1887	CLIP
1	8T1888	CLIP
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
1	8T4121	WASHER-HARD
1	8T4136	BOLT
1	0307942	ELBOW
2	0336042	SEAL-O-RING
1	1003237	GROMMET
1	1680300	MANIFOLD
1	1688974	TUBE AS
1	2041807	BRACKET AS
2	2147568	SEAL-O-RING-STOR
1	2372706	HOSE AS
1	3354225	HOSE AS
1	3410826	BRACKET AS
1	3479361	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 3.5-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.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR UPDATING FUEL LINES

MODELS INVOLVED - 385C Excavators

Dear Caterpillar Product Owner:

The fuel lines need to be updated on the products listed below. The existing fuel lines can rub and wear causing a fuel leak. You will not be charged for the service performed.

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

Please refer the dealer to their Service Letter dated 10Aug2009 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 10Aug2009 Service Letter

Rework Procedure

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This letter addresses the 246-4785 Fuel Lines Group.

NOTE: Refer to the Hydraulic Information System (HIS) in SIS Web in order to build the 335-4225 and 237-2706 Fuel Hose Assemblies.

The following parts will be needed for the first step of this update.

Image1.2.1

- Remove the two left front engine-lifting eye mounting bolts.
- Loosen the two right front engine-lifting eye mounting bolts.

Image1.3.1

- Remove the ladder clip supporting the engine harness and rotate the lifting eye out of the way.
- Loosen and uncouple the compression nut holding the front of the fuel line to the cylinder head.

Image1.4.1

- Remove the bolt securing the P-clip to the back of the front gear housing.

Image1.5.1

- Re-install the bolt without the P-clip. Tighten the bolt to a torque of 47 +/- 9 Nm (35 +/- 7 lb ft).
- The steel fuel line is connected to a hose. Remove the P-clips that secure the hose to the cylinder head and remove the hose from the filter base. Keep the bolt and washer used to secure the P-clips for reuse.
- Discard the tube, hose, and P-clips. Re-install the necessary bolts for other engine clips and brackets.

- Remove the two bolts and spacers that hold the front housing bracket to the head.
- Discard the bolts and spacers. Keep the washers for reuse.

Image1.7.1

- Using the new 0S-1619 Bolts and the washers that were saved, install the 168-0300 Fuel Manifold to the head.

Image1.8.1

- Once the manifold is bolted to the head, install a 033-6042 Seal-O-ring to each of the two 2R-6806 Connectors. Install one connector to the top of the manifold and one connector to the bottom.

Image1.9.1

- Install the new 168-8974 Fuel Tube to the top connector of the newly installed manifold and to the cylinder head.

Image1.10.1

- Re-install the bolts for the lifting eye. Tighten the bolts to a torque of 105 +/- 20 Nm (75 +/- 15 lb ft).
- Re-install the ladder clip bracket previously removed with the lifting eye. Tighten the bolts to a torque of 47 +/- 9 Nm (35 +/- 7 lb ft).

Image1.11.1

- Install the fuel sample port assembly to the bottom connector on the 168-0300 Manifold that was previously installed.

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The parts listed below will be needed for the next step of this update.

Image1.13.1

- Install the hose clamp mounting brackets to the side of block.

Image1.14.1

Image1.14.2

- Attach the 335-4225 Hose Assembly to the previously installed fuel sample port elbow.
- Route the hose through the front bracket and clamp to both brackets with the 2-piece clips and grommets.

NOTE: There is a washer under and over the 2-piece clip on the 341-0826 Front Bracket.

- Attach the other end of the hose to the fuel filter base.

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The parts below will be needed for the final step of this update.

Image1.16.1

Image1.17.1

- The current hose may be clipped with a one-piece clamp or simply laying across the flywheel housing, either of which need to be corrected.

Image1.18.1

- Remove and discard the hose and clip if present.
- Remove the regulator valve and ladder clip from the 261-8279 Bracket saving all of the hardware.
- Remove the 261-8279 Fuel Regulator Valve Bracket and replace with the new 347-9361 Bracket using the same hardware.
- Re-install the regulator valve and harness ladder clip using the same hardware.

Image1.19.1

- Install one end of the new 237-2706 Fuel Hose Assembly to the fuel regulator assembly and the other end to the elbow on the rear of the cylinder head.
- Install the 8T-1887 and 8T-1888 Two-Piece Clip with 100-3237 Grommet on the existing bracket. Tighten the 8T-4136 Bolt and 8T-4121 Washer allowing approximately 5mm clearance between the fuel hose and the corner of engine block and approximately 5mm of clearance between fuel hose and flywheel housing.

- Start machine and inspect for leaks.