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:

REBE1990-00

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22Aug2007

U-412

D-339

O-364

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES
1262 1258 1261 1263		PI31330

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31330" 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 "PI31330" 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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COMPLETION DATE	TERMINATION DATE
29Feb2008	31Aug2008

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	66600920-00921, 1053-1060, 1245-1259, 1265, 1276-1281, 1305-1314, 1878-1881, 1899-1902, 2036-2066, 2115-2122, 2126-2127, 2199-2206, 2275-2278, 2317-2323, 2329-2334, 2340-2346, 2348-2350, 2587-2594, 2614-2618, 2997-3004, 3149-3155, 3239-3251, 3369-3376

PARTS NEEDED

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Qty	Part Number	Description
4	1P4278	CLAMP-HOSE
4	2159513	CONNECTOR-SPL
4	2159515	CONNECTOR-SPL
1	3090860	FILTER AS-FUEL
1	3137111	FILTER AS-F(SEC)

ACTION REQUIRED

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Installation 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 2.5-hour job
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: Average results of the three leak-off measurement readings >50ml/30 seconds indicates a future injector failure could occur. 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 could occur, 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 replacement of the 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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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

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 the 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 are affected by this Service Letter, 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 22Aug2007 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 22Aug2007 Service Letter

Rework Procedure

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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 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 caps / plugs from 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.

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 that has been collected in the container from the leak off connector on the cylinder head.

Repeat 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 re-connected.

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.

1 SYSTEM DIAGRAM OF LOW PRESSURE FUEL SYSTEM.

Image1.5.1

2. SYSTEM FITTING:

The field re-fit kit comprises of two secondary fuel filter assemblies (309-0860 on engine and 313-7111 remote mounted) and two flexible fuel hoses (provided by OEM).

NOTE: This rework assumes that the machine is fitted with a two filter low pressure fuel system.

2.1 The secondary fuel filter assembly should be removed by disconnecting the three quick fit connectors shown below. Depress the release button and pull pipes from their spigots. Immediately plug the pipes with suitable clean plugs. Unbolt and remove the filter assembly ? do not reuse the removed filter assembly.

Image1.6.1

2.2 Remove the ECM to secondary fuel filter pipe shown below. Other low pressure fuel system components must be left on engine.

Image1.7.1

2.3 Remove the paint from around the paint shadow left by the original filter head, this is to ensure metal to metal contact all around the filter head.

Image1.8.1

2.4 FILTER ASSEMBLY:

Assembl the new secondary fuel filter assembly (309-0860) onto the mounting bracket reusing the two M10 setscrews and tighten them to a torque of 55Nm +/- 10Nm.
Ensure all filter ports remain plugged until the pipes are to be fitted ? reconnect the three fuel lines to their original positions. (as in section 2.1).

2.5 REMOTE MOUNTED FILTER:

Assemble the remote mounted fuel filter (313-7111) to the chassis. Connect a flexible fuel hose between points "A" and "B" and points "C" and "D", use the ISO quick fit spigots supplied fitted to the filter assembly or remove these and use suitable alternatives. Connection "E" must not be modified. Make a flexible hose from a suitable hose to Specification SAEJ30R9, 4 clamps part no.1P4278 and a selection of connectors as required from part no.s 215-9515 (90degree) and 215-9513 (straight connector). The required internal diameter needs to be 8mm

Image1.9.1

2.6 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.