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:

REBE2295-00

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22Aug2007

U-411

A-338

D-338

O-363

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES
1262 1258 1261 1263 1274		PI31329

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31329" 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 "PI31329" 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

66600373, 383-390, 392-404, 406-410, 412-413, 415-428, 440-443, 456-465, 467-472, 474-483, 550-554, 556-564, 566-593, 596-601, 603, 606-615, 635-649, 676-677, 679-695, 697-710, 825-829, 843-862, 870-884, 899-913, 938-944, 962-966, 968-986, 1004, 1109-1113, 1131-1135, 1137-1151, 1153-1155, 1179-1180, 1182, 1195, 1197-1199, 1266-1275, 1282-1288, 1290-1295, 1297-1300, 1316-1326, 1328, 1333-1341, 1343-1348, 1352-1361, 1401-1403, 1419-1429, 1432-1433, 1436, 1438-1439, 1441-1442, 1493-1509, 1511-1521, 1534-1562, 1564-1565, 1568-1598, 1601, 1603-1606, 1608, 1611-1620, 1622-1634, 1636-1658, 1696-1700, 1702, 1704-1706, 1709-1714, 1716-1735, 1737-1740, 1742-1745, 1761, 1763, 1765-1767, 1769-1770, 1773-1776, 1778-1780, 1782-1783, 1787-1795, 1797-1801, 1804-1824, 1826, 1828, 1830-1839, 1841-1844, 1846-1853, 1856-1867, 1882-1887, 1904, 1909-1911, 1913-1920, 1922-1929, 1931, 1933-1935, 1938-1956, 1958-1961, 1964, 1967-1968, 1971, 1973, 1976-1977, 1983-1985, 1989-1991, 1993, 2005-2010, 2012, 2089-2094, 2099-2100, 2102, 2398, 2401, 2404, 2407-2408, 2920-2926, 2990, 2993-2996, 3085-3086, 3088, 3091-3109, 3112, 3157, 3162-3166, 3177, 3179

PARTS NEEDED

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Qty	Part Number	Description
1	3087480	FILTER AS-FUEL
1	3176281	SPACER

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
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 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

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 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 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 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 the average fuel volume for the 3 leak off measurement readings is >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 element (308-7480) and a 5mm spacer to fit between the filter head and its bracket (317-6281).
The spacer can be manufactured locally ? see component drawing at the end of this letter.

2.1 REMOVAL OF EXISTING COMPONENTS.

The new filter element (308-7480) is slightly larger in diameter than the one currently fitted. To enable the new filter to be assembled a spacer plate needs to be fitted between the filter head and the existing mounting bracket.

DO NOT DISCONNECT LOW PRESSURE FUEL LINES.

Remove the two bolts (A) part No. 6I-0593 that secure the filter assembly to its bracket ? refer to image 1.6.1.

Image1.6.1

3.1 RE-ASSEMBLY.

While supporting the filter assembly, insert the spacer 317-6281 behind the filter head until the holes are aligned.

Bolt the filter assembly and spacer back to the bracket using new 111-0859 M10 X 35mm flanged bolts and tighten to a torque of 55Nm +/- 10Nm.

Image1.7.1

3.2 REPLACING THE FUEL FILTER CANISTER.

Isolate the fuel supply from the reservoir via the valve (where fitted).

Place a suitable container under the secondary fuel filter to catch any fuel, which may be released. Clean the outside of the fuel filter body. Use a suitable tool to unscrew / remove the original fuel filter canister.

Ensure that the new filter is kept clean until it is required to be fitted, lubricate the "O" ring seal with clean fuel ? DO NOT PRE FILL THE FILTER.

Install the new 308-7480 Filter canister to the filter head and tighten by hand.

Dispose of the old filter canister and any fuel, safely - in line with local regulations and your warranty bulletin.

3.3 CLEARANCE BETWEEN COMPONENTS

The clearance between the underside of the new secondary fuel filter canister and the fuel leak off pipe from the high-pressure fuel pump may be reduced. A piece of rubber hose or spiral wrap MUST be fitted to the high pressure pump leak off line where it runs under the fuel filter canister to protect against abrasion.

Image1.8.1

3.4 PRIMING THE FUEL SYSTEM.

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.

3.4 DIMENSIONS OF SPACER.

All dimensions are in mm ? the spacer thickness is 5.0mm