PRODUCT SUPPORT PROGRAM FOR REWORKING THE 271-3840 AND 278-0558 FUEL COOLER LINES GROUPS ON CERTAIN C32 AND C27 GENSETS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE 271-3840 AND 278-0558 FUEL COOLER LINES GROUPS ON CERTAIN C32 AND C27 GENSETS

Usage:

REBE2517-00

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25Sep2007

U-481

A-393

D-385

O-413

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE 271-3840 AND 278-0558 FUEL COOLER LINES GROUPS ON CERTAIN C32 AND C27 GENSETS
1712 1274		PS42521

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NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42521" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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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TERMINATION DATE

30Sep2009

PROBLEM

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The existing 271-3840 Lines Group on certain C32 Gensets and 278-0558 Lines Group on certain C27 Gensets can leak. If the existing lines group fails it will leak at the 2H-9091 Fitting.

AFFECTED PRODUCT

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Model	Identification Number
C27	DWB00103-00160, 162-229, 231-237, 239-264, 266-318, 320-328, 330-359, 362-424, 426-427, 430-431, 433-493, 495-536, 538-547, 553-556, 563-606, 608-611, 613-614, 616-619
C32	SXC00592-00593, 607, 612, 614-615, 617, 621, 627, 632-636, 639-642, 645, 649-650, 652-653, 656, 658, 660-661, 665-676, 678-923, 925-987, 989-1038, 1040-1054, 1056, 1059-1103, 1105-1115, 1117-1135, 1137-1140, 1143-1203, 1205-1216, 1219-1225, 1227-1239, 1241-1335, 1337-1383, 1388-1392, 1395-1434, 1436, 1438-1444, 1446-1467, 1469-1486, 1489-1500, 1503-1510, 1513-1519, 1522-1539, 1541, 1543-1564, 1566-1568, 1572, 1576-1577, 1579-1580, 1582-1592, 1594-1599, 1601-1608, 1611-1627, 1630-1641, 1643-1682, 1686-1692, 1699-1713, 1717, 1721-1726, 1736-1744, 1746-1771, 1774-1776, 1783-1791, 1794, 1796-1827, 1832, 1834-1839, 1843-1853, 1855, 1857-1870, 1877, 1881-1883, 1885, 1889, 1893, 1909-1910, 1912-1913

PARTS NEEDED

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Qty	Part Number	Description
1	1550695	THREAD LOCK (Multiple repairs per qty of 1)

ACTION REQUIRED

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Please remove the 2H-9091 fluid line connector fittings from the lines groups. Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-9999 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 2.0-hour job
The preferred method is for this to be performed by two people for 1 hour.

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Recommended Tools:
1. 1- 9/16" socket
2. 2- 1" wrench
3. 1- 16 mm socket
4. 1- 27 mm wrench

This rework procedure can be used for the following lines groups.
C27: 278-0558 lines group
C32: 271-3840 lines group

Image1.1.1

Image1.1.2

Both image 1.1.1 and 1.1.2 are provided to give a location reference.

For further clarification regarding the disassembly/assembly of the C32 or the C27, refer to D & A Manual RENR9716.

1. Loosen the p-clip on the rail assembly and the radiator.
Loosen the rail p-clip with a 16mm socket.
Loosen the radiator p-clip with a 16mm socket.

2. Rotate the top half of the fan guard away from the fuel cooler connections.
Use a 9/16" socket for the bolts that join the two halves together.
Use a 1 6mm socket for the bolts that attach guard to radiator shroud.

3. Hold the fuel cooler fitting with a 1" wrench and remove the 2H-9091 with a 1" wrench.

4. Hold the hose assembly with a 27 mm wrench and remove the 2H-9091 Coupling with a 1" wrench.

5. Apply 155-0695 sealant to the hose assembly.

6. Reattach the hose assembly and thread the hose assembly into the fuel cooler by hand.

7. Tighten the hose assembly to to a torque of 40 Nm by holding the fuel cooler with a 1" wrench and turning the hose assembly with a 27 mm wrench.

8. After installing the hose assembly reattach the fan guard and tighten the fuel line p-clips.