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

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

Usage:

REBE1947-02

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02Oct2007

(Revised 04Mar2008)

U-500

A-411

D-402

O-433

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES
1262 1258 1261 1263 1274		PI31363

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31363" 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 "PI31363" 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 24Oct2007 Service Letter. Changes have been made to Affected Product.

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COMPLETION DATE	TERMINATION DATE
30Apr2008	31Oct2008

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
*****Group 1*****
C6.6 TIER 3	66600211, 233-236, 247, 264, 286-289, 305-307, 309, 323, 349-350, 354-355, 372, 377, 391, 429, 484-485, 524-540, 542-543, 594, 604-605, 716-718, 749, 813-819, 922, 1041-1044, 1181, 1315, 1377-1379, 1381-1388, 1444-1445, 1447-1452, 1473-1487, 1566, 1602, 1635, 1701, 1703, 1707-1708, 1741, 1748-1750, 1757, 1764, 1768, 1771-1772, 1777, 1781, 1784-1786, 1796, 1825, 1827, 1829, 1840, 1845, 1855, 1905-1908, 1912, 1921, 1936, 1957, 1965, 1969, 1974-1975, 1981, 1986-1987, 1992, 1994-2000, 2095-2096, 2098, 2101, 2137, 2173, 2181-2192, 2253-2262, 2289-2293, 2296-2308, 2312-2316, 2335-2339, 2351-2355, 2362-2365, 2368-2372, 2388-2391, 2394-2397, 2399-2400, 2402-2403, 2405-2406, 2421-2428, 2432-2438, 2442, 2453-2469, 2485-2488, 2595-2606, 2648-2652, 2662-2666, 2668-2670, 2679-2681, 2875-2886, 3159, 3178, 3213-3224, 3377, 3405, 3426-3460, 3496-3528, 3538-3545, 3547-3566, 3577-3581, 3583-3597, 3599-3620

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*****Group 2*****
C6.6 TIER 3	66601890, 2108, 2227, 2409-2412, 2508-2509, 2736, 2758-2759, 3119, 3322-3329, 3537

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	6I0260	BOLT
2	6I0593	BOLT
2	2343063	CLIP
1	2776165	CONNECTION-FUEL
1	3087480	FILTER AS-FUEL
1	3111159	TUBE FILTER-FUEL
1	3111175	TUBE-LEAK OFF
1	3111666	BRACKET
1	3111684	TUBE
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 inital 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	6I0260	BOLT
2	6I0593	BOLT
2	2343063	CLIP
1	2776165	CONNECTION-FUEL
1	3087480	FILTER AS-FUEL
1	3111166	TUBE - LEAK OFF
1	3111288	TUBE FILTER-FUEL
1	3111666	BRACKET
1	3111684	TUBE
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 inital 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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Installation of improved fuel filter arrangement. 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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.5-hour job for Group 1
NOTE: The breakdown for the 2.5 hour job, is as follows: 1.5 hours will be allowed for a diagnostic leak off check and 1.0 hour will be allowed for the installation of the improved fuel filter arrangement. NOTE: If the average results of the three leak-off measurement readings >50ml/30 seconds indicates a future injector failure exists. A high leak-off 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 apply the improved filter arrangement only, return the machine into service, and schedule the additional components at a later date. The time and cost for additional components for the fuel system 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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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 2.5-hour job for Group 2
NOTE: The breakdown for the 2.5 hour job, is as follows: 1.5 hours will be allowed for a diagnostic leak off check and 1.0 hour will be allowed for the installation of the improved fuel filter arrangement. NOTE: If the average results of the three leak-off measurement readings >50ml/30 seconds indicates 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 apply the improved filter arrangement only, return the machine into service, and schedule the additional components at a later date. The time and cost for additional components for the fuel system 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.

PARTS DISPOSITION

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

Dear Caterpillar Product Owner:

The filtration system prior to the introduction of this service letter 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. The fuel filter arrangement needs to be replaced on the products listed below.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. You will not be charged for this service.

Please refer the dealer to their Service Letter dated 02Oct2007 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 02Oct2007 Service Letter

Rework Procedure

Important Notes:

Common rail fuel technology requires a high degree of cleanliness. 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 components that are 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 clamps are 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.

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 clamps 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 clamp (5). Place the rubber hose assembly (3) onto the end of the fuel leak off pipe (2) and tighten the hose clamp (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 from the leak off connector on the cylinder head which is in the container.

Repeat the test a total of 3 times.

If the 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 re-connected.

1. SYSTEM DIAGRAM OF LOW PRESSURE FUEL SYSTEM.

Image1.5.1

2. SYSTEM FITTING

The field re-fit kit contains a secondary fuel filter assembly, a fuel filter bracket, a nylon fuel pipe (ECM to secondary fuel filter), a nylon and steel pipe (Leak off / fuel return), a steel fuel pipe (secondary fuel filter to high pressure fuel pump inlet), two pipe clamps and a connector 277-6165.

2.1. REMOVAL OF EXISTING COMPONENTS.

Remove the three low pressure fuel pipes which are identified as A,B & C in image 1.6.1 below including the two sets of pipe clamps (circled). Pipes A & B have quick release connectors (depress then release the button and pull the connector from its spigot). Pipe C may be steel or plastic in construction, if it is steel release the compression nuts nearest the spigot ends and remove the pipe leaving the nuts / olives in place ? if it is plastic then remove by releasing the quick connectors.

Immediately cap all open ends.

Image1.6.1

Remove the two setscrews that secure the filter head assembly to its mounting bracket and remove the filter assembly. Then remove the two setscrews securing the mounting bracket to the induction manifold. The filter assembly and old mounting bracket shown in Image 1.7.1 will not be re-used.

Image1.7.1

3. ASSEMBLY OF NEW COMPONENTS.

Assemble the new 311-1666 Filter Bracket to the induction manifold cover using two 6I-0260 Setscrews and tighten to 22Nm +/- 5.5Nm.

Image1.8.1

3.1. Assemble the new 308-7480 Fuel Filter Assembly to the new bracket using two 6I-0593 Setscrews and tighten to 55Nm +/-10Nm.

Image1.9.1

3.2. Fit the new leak off pipe assembly, part number 311-1166 for Group 2 or 311-1175 for Group 1, in the position shown in Image 1.10.1. Connect the quick connector to the fuel pump leak off spigot A, the quick connector to the filter bleed spigot B and assemble the steel injector leak off pipe to the pressure relief valve in the fuel rail C. (using fitting 277-6165) Put the nut then olive onto the pipe end, push the pipe fully into the fitting, and tighten the nut by hand.
If the original fitting in the fuel rail is damaged - replace it, otherwise just use the nut and olive from the new connector.

Ensure the body of the fitting does not move (using an open ended wrench) tighten the nut to 26Nm +/- 4Nm for a steel fitting or 21Nm +/- 4Nm for a brass fitting.
Press the pipe assembly into the five clamps ? circled in Image 1.10.1

Image1.10.1

3.3. Assemble the 311-1687 steel pipe as shown in Image 1.11.1. Locate both compression fittings as far as possible onto the filter outlet and pump inlet spigots. Tighten all four nuts to either 26Nm +/- 4Nm for steel fittings or 21Nm +/- 4Nm for brass fittings.

If a compression fitting has already been assembled to a spigot the assembly process is modified as follows ? tighten the nut until a sharp rise in torque is felt, then tighten another 1/3 of a turn. A special tool such as a bent wrench will be required on the lower fitting due to limited access.

Image1.11.1

3.4. Assemble the low pressure fuel pipe, part number 311-1288 for Group 2 or 311-1159 for Group 1, to the position shown in Image 1.12.1. Attach one end to the ECM spigot A and the other to the secondary filter inlet spigot B. Fit two 234-3063 Pipe Clips and clip the pipe onto the brackets where circled in Image 1.12.1.

Image1.12.1

3.5. Prime the fuel system as directed in the Systems Operation Test and Adjust section ? Fuel system prime.

Run the engine and check for fuel leakage ? rectify as necessary.