PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES IN ROCKDRILL APPLICATIONS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES IN ROCKDRILL APPLICATIONS

Usage:

REBE1706-01

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11Apr2007

(Revised 25Mar2008)

U-133

A-117

D-113

O-120

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES IN ROCKDRILL APPLICATIONS
1262 1258 1261 1263		PI31240

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31240" 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 "PI31240" 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:	This Revised Service Letter replaces the 11Apr2007 Service Letter. Changes have been made to Mail Codes.

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COMPLETION DATE	TERMINATION DATE
31Oct2007	30Apr2008

PROBLEM

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Excess contamination in the fuel is causing accelerated wear on the injectors.

AFFECTED PRODUCT

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Model	Identification Number
C6.6 TIER 3	66600292, 667, 713-714, 724, 728, 734, 740, 799, 802, 887-889, 892, 894, 1022, 1024-1026, 1029-1033, 1039-1040, 1114, 1119-1120, 1125, 1127, 1129-1130, 1183, 1191, 1193-1194, 1404-1405, 1408, 1410-1412, 1416-1418, 1691

PARTS NEEDED

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Qty	Part Number	Description
1	1B2790	BOLT
2	1P0436	GASKET-PRM PUMP
1	1R0751	FILTER AS-FUEL
1	1R0770	FILTER AS-SEP
1	3K0360	SEAL-O-RING
1	5P0537	WASHER-HARD
2	6I0217	BOLT
3	6I0218	BOLT
1	6I0254	BOLT
2	6I0594	NUT
1	6I0917	BOLT
1	6K3607	CONNECTOR-FLARED
1	6N4414	COVER-FLTR BASE
5	6V5048	SEAL-O-RING
1	7B2742	BOLT
1	7L9061	SEAL-O-RING
1	8M0505	CONNECTOR-FLARED
1	8M0547	ELBOW
1	9M1974	WASHER-HARD
1	9S4182	PLUG-O-RING
4	9S8002	PLUG-O-RING
2	1004830	BOLT
1	1013895	BOLT
1	1127704	BOLT
1	1415138	BASE AS-F FILTER
1	1832823	PUMP AS-F PRM
1	2029871	BASE AS.
1	2705320	BOWL AS-FWS
1	2776165	CONNECTION-FUEL
1	3030356	HOSE
1	3030359	FILTER AS
1	3030361	BRACKET AS
1	3030367	TUBE AS
1	3030369	TUBE (LEAK-OFF)
1	3030370	HOSE
1	3030387	CONNECT INLET
1	3030392	CONNECT INLET
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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Addition of an improved fuel filter arrangement.

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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 4.5-hour job
NOTE: The breakdown for the 4.5 hour job, is as follows: 1.5 hours will be allowed for a diagnostic leak off check and 3.0 hours will be allowed for the addition of the improved fuel filter arrangement. NOTE: If the average results of the three leak-off measurement readings are >50ml/30 seconds, then a future injector failure exists. A high leakoff test should initiate a replacement of the fuel system components. If the outcome of the leak-off test indicates that a future injector failure exists, it is perfectly acceptable to return the machine into service and to apply the improved filter arrangement only, and schedule the additional components at a later date. The time and cost for additional components for the fuel system replacement, should be submitted to Caterpillar as a separate warranty claim from the improved filter arrangement. Use the injector part number as the part causing failure.

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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 FUEL FILTER ARRANGEMENT

MODELS INVOLVED - CERTAIN C6.6 ENGINES IN ROCKDRILL APPLICATIONS

Dear Caterpillar Product Owner:

The filtration system could allow particles to get through and damage the injectors causing high leak off and inability to start. The new improved filtration system will prevent this from happening and increase the protection of the injectors.

If your engine is in the list of engines that this service letter refers order the parts required and fit them as per this instruction.

Please refer the dealer to their Service Letter dated 11Apr2007 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 11Apr2007 Service Letter

Rework Procedure

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ELECTRONIC UNIT INJECTOR LEAK OFF TEST.

Ensure the fuel system components (and the surrounding area) are cleaned externally and free from debris prior to breaking into the fuel system (( see the section (Engine Clean)) in the OMM.

Ensure that the engine is shut down. Locate the fuel leak off
connector (1) on the cylinder head.

Image1.1.1

Remove the leak off pipe (2) from the connection on the cylinder head (1). Use a clean rubber hose, two hose clips and a suitable bolt to make a sealed cap (3) for the end of the fuel leak off pipe
(2). Insert a bolt (4) into the end of the rubber hose (6). Secure the bolt to the rubber hose with a hose clip (5). Place the rubber hose assembly (3) onto the end of the fuel leak off pipe (2) and tighten the hose clip (7).

Image1.2.1

Push a clean length of plastic hose (8) onto the leak off connector (1) on the cylinder head. Place the opposite end of the plastic hose (8) into a clean, graduated fuel container (9).

Image1.3.1

Disconnect the three wiring harness connectors (10) on the top cover in order to prevent the engine from starting.

Image1.4.1

Crank the engine with the starter motor for 30 seconds.
Record the amount of fuel that has been collected in the container from the leak off connector on the cylinder head.

Repeat the test a total of 3 times.

If an average fuel volume for the 3 leak off measurement readings are >50ml/30 seconds then the following fuel system components will also be required to be changed:

6 x Injectors
6 x High-pressure pipes (from fuel rail to injector)
6 x Injector clamp bolt(278-5170)
6 x Top cover sleeve(277-5067)

If the average fuel volume for the 3 leak off measurement readings are <50ml/30 seconds then no additional fuel system components are required and only the addition of the improved fuel filter assemblies, outlined in this PI need to be applied.

The leak off pipe (1) should be re-connected to the cylinder head and the three wiring harness plugs (10) should be reconnected.

REWORK FOR IMPROVED FUEL FILTER ARRANGEMENT

Important Notes:

The fuel system is very sensitive to particle size. It is therefore imperative to adhere to all cleanliness requirements within this rework instruction, for example re-using dirty caps will have a detrimental effect on product durability.

Parts must be inspected prior to use to ensure capping is intact and parts are clean and undamaged.

All new components should remain bagged and capped until immediately before use.

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 low pressure pipe is removed.
Use anti contamination kit part No.278-4138.

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

Clean up any spilt fuel before undertaking further work.

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

NO attempt should be made to clean / flush filter elements for re-use.

DO NOT PRE-FILL THE FILTERS.

Fuel can be hot after 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.

Ensure all fuel system components (and the surrounding area) are cleaned externally and free from debris, prior to removing fuel system components - see section (Engine Clean) in the OMM.

Isolate fuel supply at the valve on the tank and isolate power at the isolator to ensure the engine can not be cranked.

Remove the fuel pipe shown in figure 1.5.1, which fits between the fuel filter and ECM fuel outlet connector along with the two pipe clips. Ensure that all connections are capped - use anti contamination kit 278-4138.

Image1.5.1

Remove the fuel pipe shown in figure 1.6.1, which fits between the fuel filter and the high pressure pump (this can be discarded) ensuring the high pressure pump connection is capped.
Disconnect the air bleed pipe connection from the top of the fuel filter. Remove the fuel filter assembly and its mounting plate.

Image1.6.1

Disconnect and remove the low pressure fuel line assembly as shown in figure 1.7.1 discard the fuel line and cap the open connections.
Remove the pipe support bracket shown in figure 1.7.2 and discard. Fit bracket 303-0361 to the induction cover using three fixings (part 6I-0218) and torque them to 28Nm +/- 7Nm as per figure 1.7.3

Image1.7.1

Image1.7.2

Image1.7.3

Fit pipe 303-0369 to the common rail relief valve (1) as shown in figure 1.8.1 - the fuel pump leak off quick connector (2) and the upper pipe support clip (3). At the relief valve replace the connection part number 277-6165. Push the pipe fully into the fitting and tighten the nut by hand. Ensure the body of the fitting does not move and tighten the nut 1 and 1/4 turns.

Image1.8.1

Fit fuel filter assembly 303-0359 to bracket 303-0361 on the induction cover using two 6I-0594 fixings and torque to 55Nm +/- 10Nm as per figure 1.9.1

Fit the steel pipe assembly 303-0367 to the fuel pump inlet spigot and final filter outlet as shown in Image 1.9.2, Push both ends fully home. Tighten the nuts by hand. Ensure the body of the fitting does not move and tighten the nuts 1 1/4 turns.Access to the lower fitting is restricted and a crows foot type offset wrench may be required.

Image1.9.1

Image1.9.2

Remove the primary filter and move the bracket to the next position forward on the cylinder block. Drill new holes in the adapter to fit the new primary filter. Assemble the new primary filter group with the priming pump fitted vertically see Image 1.10.1.

Fit the 90 deg connector (8M-0547) on the fuel outlet connection of the primary filter.

Image1.10.1

Manufacture the bracket shown in Image 1.11.1, and mount it were the old primary filter was placed. Assemble the intermediate filter group shown in Image 1.11.2 and mount it on the bracket.

Connect the existing hose (a) from the machine fuel tank to the inlet of the primary filter as shown in Image 1.11.3.

Connect the existing hose (b) from the fuel transfer pump to the outlet of the primary filter.

Connect the hose (c) 303-0356 to the ECM outlet and the intermediate filter inlet.

Connect the hose (d) 303-0370 to the intermediate filter outlet and the fuel inlet on the final filter.

Image1.11.1

Image1.11.2

Image1.11.3

The hoses need to be secured on the frame to avoid rubbing shown in Image 1.12.1

Image1.12.1

Prime the fuel system as directed in the Systems Operation Test & Adjust section - Fuel system prime.

Run the engine and check for fuel leakage, rectify as appropriate.