PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL LINES ON CERTAIN 365C EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL LINES ON CERTAIN 365C EXCAVATORS

Usage:

REBE5310-00

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10Jul2009

U-258

A-220

D-224

O-230

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE FUEL LINES ON CERTAIN 365C EXCAVATORS
1274		PI31672

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31672" 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 "PI31672" 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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COMPLETION DATE	TERMINATION DATE
31Jan2010	31Jul2010

PROBLEM

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A fuel leak may result from the existing fuel hose configuration, allowing the fuel hose to rub against the 236-9862 Breather Tube and/or the 239-5929 Engine Harness on certain 365C Excavators.

A fuel leak may result from the existing fuel tube configuration allowing the fuel tube to rub against the 6V3265 P-clip.

AFFECTED PRODUCT

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Model	Identification Number
365C L	ELC00157, 161, 164, 172, 187, 189, 196, 200, 221-222, 227, 231-233, 237, 261, 267, 270, 275, 277-278, 287, 292-293, 295-296, 298, 300-302, 304, 330-332, 335, 360, 367, 373-377, 389-391, 393, 402, 438-439 FEN00117-00147 MCS00180, 215, 218-219, 225-226, 234, 239, 246, 251, 269, 273-275, 284, 287-288, 290, 310, 312, 325, 355, 373, 383, 392, 406, 412, 437, 443, 446-447, 460, 465, 482 MCY00185-00187, 195, 198, 202, 204, 217, 228-229, 232-234, 241, 246, 256, 259, 261, 268, 278, 286, 297, 304, 310, 316, 319, 321, 331, 335, 353, 360-362, 369-370, 374, 389, 394, 403-404, 406, 410, 412, 416, 419, 423, 425, 430-431, 433, 444 MEM00173, 179, 196, 201, 204, 206, 210, 213-214, 217, 233, 236, 251, 253, 260, 262-263, 265, 267, 273-274
365C L FS	PAR00253, 257-259, 267-268
365C L OEM	GSZ00102-00103, 122, 127, 129-130, 134
CIPI	0EM01397, 1417, 1479, 1674, 1960, 1973

PARTS NEEDED

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Qty	Part Number	Description
2	0S1619	BOLT
2	2R6806	CONNECTOR
1	5I3190	FITTING
1	6V0852	CAP-DUST
1	6V3965	NIPPLE AS
2	7V6571	GROMMET
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
2	8T4121	WASHER-HARD
2	8T4136	BOLT
2	0336042	SEAL-O-RING
1	1165263	HOSE AS
1	1629728	BRACKET AS.
1	1680300	MANIFOLD
1	1688974	TUBE AS
1	1861667	CONNECTOR AS
2	2147568	SEAL-O-RING-STOR
1	2822593	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 2.5-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 REPLACING THE 255-2955 FUEL LINE AND 244-7592 FUEL TUBE ON CERTAIN 365C EXCAVATORS

MODELS INVOLVED - 365C Excavators

Dear Caterpillar Product Owner:

The 255-2955 fuel line and 244-7592 fuel tube need to be replaced on the products listed below. A fuel leak may result from the existing fuel hose configuration allowing the fuel hose to rub against the 236-9862 Breather Tube and/or the 239-5929 Engine Harness. A fuel leak may result from the existing fuel tube configuration allowing the fuel tube to rub against the 6V3265 P-Clip.

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 10Jul2009 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 10Jul2009 Service Letter

Rework Procedure

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*****Prior to starting this update, refer to the Hydraulic Information System in SIS in order to construct the 116-5263 Fuel hose.*****

1. Remove the left two front engine lifting eye mounting bolts.

2. Loosen the right two front engine lifting eye mounting bolts.

Image1.1.1

3. Remove the ladder clip supporting the engine harness and rotate the lifting eye out of the way.

4. Undo the compression nut holding the front of the fuel line to the cylinder head.

Image1.2.1

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

Image1.3.1

6. Re-install the bolt without the P clip. Tighten the bolt to torque of 47 +/- 9 N.m (35 +/- 7 lb ft).

7. The steel tube on the fuel line connects to a hose. Remove the P clip that secures the fuel hose to the cylinder head and remove the fuel hose from the fuel filter base. Keep the bolt and washer used to secure the p-clips for re-use. Image 1.4.1
- Do not reuse the tube, hose and P clips. Re-install bolts necessary for other engine clips and brackets.

Image1.4.1

8. Remove the two bolts and spacers that hold the front housing bracket to the head.
- Do not reuse the bolts and spacers. Retain the washers for reuse. Image 1.5.1

Image1.5.1

9. Install the 168-0300 Fuel Manifold to the head using the new 0S-1619 bolts and the washers that were retained in Step 8.

Image1.6.1

10. Once the manifold is bolted to the head, install one 033-6042 o-ring each on two of the 2R-6806 connectors. Install one connector to the top of the manifold and one connector to the bottom. Image 1.7.1

Image1.7.1

11. Install the new 168-8974 fuel tube to the top connector and to the cylinder head.

Image1.8.1

12. Re-install the bolts for the lifting eye. Tighten to a torque of 105 +/- 20 N.m (75 +/- 15 lb ft).

13. Re-install the ladder clip bracket previously removed with the lifting eye. Tighten to a torque of 47 +/- 9 N.m (35 +/- 7 lb ft).

14. Install the fuel sample port assembly to the bottom connector installed on the 168-03033 manifold installed in Step 10.

Image1.10.1

15. Connect one end of the previously made 116-5263 Hose Assembly to the previously installed fuel sample port.
- Route the 116-5263 Fuel hose behind the Inlet Manifold Pressure sensor harness and behind the ether line, if present. Also, route the fuel hose to the outside of the breather tube.

16. Connect the hose to the fuel filter base.

17. Install the 162-9728 bracket to the bottom right bolt of the intake air tube.

18. Assemble the 2 piece clip, grommet, bolt, and washer (8T-1889, 8T-1890, 7V-6571, 8T-4136, and 8T-4121) to the 162-9728 bracket and 116-5263 fuel hose.