PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES
Usage:
REBE2730-01
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| 27Nov2007 |
| (Revised 03Mar2008) |
U-611
A-497
O-533
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| Before/After | PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES |
|
| 1262 1258 1261 1263 1274 | PS42566 |
|
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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 "PS42566" 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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| NOTE: | This Revised Service Letter replaces the 27Nov2007 Service Letter. Changes have been made to the Parts Needed, Action Required, and Rework Procedure. |
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TERMINATION DATE |
| 30Nov2009 |
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 | N6D00100-00649 SDA00109-00759 |
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| *******Group 2******* | |
| C6.6 TIER 3 | 66603494, 3859-3863, 3889-3890 |
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| *******Group 3******* | |
| C6.6 TIER 3 | 66601689, 1747, 2026-2032, 2309-2310, 2751-2753, 2928-2929, 2974, 3063, 3065, 3142-3145, 3190-3192, 3530-3531, 3834, 4151-4152, 4263, 4598-4601, 5057, 5076, 5417-5419, 6155-6157 |
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| *******Group 4******* | |
| C6.6 TIER 3 | 66600382, 473, 486-487, 616-618, 620-628, 824, 1398, 1685-1687, 1690, 1693-1695, 2103-2107, 2165, 2193, 2367, 2931-2932, 3030-3047, 3330-3339, 3378-3383, 3386-3387, 4220-4221, 4482-4483, 4643, 4743-4749, 4820-4829, 5367-5368 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 2 | 6I0593 | BOLT |
| 2 | 6I0594 | NUT |
| 1 | 2343063 | CLIP |
| 1 | 2776165 | CONNECTION-FUEL |
| 1 | 3087480 | FILTER AS-FUEL |
| 1 | 3111331 | TUBE-FUEL |
| 1 | 3111677 | TUBE-LEAK OFF |
| 1 | 3111721 | TUBE PUMP-FILTER |
| 1 | 3111737 | BRACKET AS |
| 1 | 3197348 | BRACKET AS-SPRT |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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. | ||
| *******Group 2******* | ||
| 2 | 6I0593 | BOLT |
| 2 | 6I0594 | NUT |
| 1 | 2343063 | CLIP |
| 1 | 2776165 | CONNECTION-FUEL |
| 1 | 3087480 | FILTER AS-FUEL |
| 1 | 3111331 | TUBE-FUEL |
| 1 | 3111677 | TUBE-LEAK OFF |
| 1 | 3111721 | TUBE PUMP-FILTER |
| 1 | 3111737 | BRACKET AS |
| 1 | 3197344 | COVER AS-PROT |
| 1 | 3197345 | BRACKET-COVER |
| 1 | 3197348 | BRACKET AS-SPRT |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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. | ||
| *******Group 3******* | ||
| 2 | 6I0593 | BOLT |
| 2 | 6I0594 | NUT |
| 1 | 2343063 | CLIP |
| 1 | 2776165 | CONNECTION-FUEL |
| 1 | 3087480 | FILTER AS-FUEL |
| 1 | 3111293 | TUBE-FUEL |
| 1 | 3111675 | TUBE-LEAK OFF |
| 1 | 3111721 | TUBE PUMP-FILTER |
| 1 | 3111737 | BRACKET AS |
| 1 | 3197344 | COVER AS-PROT |
| 1 | 3197345 | BRACKET-COVER |
| 1 | 3197348 | BRACKET AS-SPRT |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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. | ||
| *******Group 4******* | ||
| 2 | 6I0593 | BOLT |
| 2 | 6I0594 | NUT |
| 1 | 2343063 | CLIP |
| 1 | 2776165 | CONNECTION-FUEL |
| 1 | 3087480 | FILTER AS-FUEL |
| 1 | 3111331 | TUBE-FUEL |
| 1 | 3111677 | TUBE-LEAK OFF |
| 1 | 3111721 | TUBE PUMP-FILTER |
| 1 | 3111737 | BRACKET AS |
| 1 | 3197348 | BRACKET AS-SPRT |
| In Order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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| Groups 1 and 4 require updates to the fuel filtration. Groups 2 and 3 require updates to the fuel filtration and installation of a protective cover. Refer to the attached Rework Procedure |
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SERVICE CLAIM ALLOWANCES
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| *******Group 1******* | ||||||
0-24 mo |
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| NOTE: This is a 2.5-hour job for Group 1 | ||||||
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| *******Group 2******* | ||||||
0-24 mo |
||||||
| NOTE: This is a 2.5-hour job for Group 2 | ||||||
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| *******Group 3******* | ||||||
0-24 mo |
||||||
| NOTE: This is a 2.5-hour job for Group 3 | ||||||
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| *******Group 4******* | ||||||
0-24 mo |
||||||
| NOTE: This is a 2.5-hour job for Group 4 | ||||||
PARTS DISPOSITION
| Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. |
| PRODUCT SUPPORT PROGRAM FOR FITTING AN IMPROVED FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES. PROBLEM: Excess contamination in the fuel is causing accelerated wear of the injectors. 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. Refer to Special Instruction ? KENR6938 ? High leak off of the electronic unit injector. 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. 1 SYSTEM DIAGRAM OF LOW PRESSURE FUEL SYSTEM. |
|
| Image1.1.1 |
| 2. SYSTEM FITTING The field re-fit kit consists of 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), a protective cover assembly (Not required for engine reworks in Group1 and 4), a bracket for the protective cover (Not required for engine reworks in Groups 1 and 4), and a low pressure fuel pipe connector. 2.1 REMOVAL OF EXISTING COMPONENTS. Remove the 294-7960 Protective Cover (item 1 in 1.2.1) to access the fuel system. |
|
| Image1.2.1 |
| Remove Primary fuel filter (A shown below) from its bracket and cap all open ports immediately using caps / plugs from anti contamination kit 278-4138. Remove the low pressure pipes identified as follows: (2), (3), and (4) in Image 1.3.1. Remove the pipe to pipe securing clamps (circled below). To release pipes 2, 3, and 4 quick connectors, depress the release button and pull the pipe from its spigot ? cap the spigots. If a steel version of pipe 4 is fitted, with compression fittings ? completely undo the nut nearest the spigot and remove the pipe assembly. Leave the nut and olive in place and again cap the spigot. |
|
| Image1.3.1 |
| Undo the two bolts to remove the 313-7118 Bracket (Item 5 shown below). |
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| Image1.4.1 |
| 3.0 ASSEMBLY OF NEW COMPONENTS. Fuel filter and spacer bracket. 3.1 Assemble 311-1737 Spacer (2) to the fuel filter bracket (see below) use 6I-0594 2 X M10 flanged nuts (1) and tighten to a torque of 55Nm +/- 1Nm. Assemble 308-7480 Fuel Filter assembly (3) with the 319-7345 Protective cover bracket (4) - (Not required for engine reworks in Groups 1 and 4) onto the filter mounting bracket using 2 X M10 flange head bolts (5) part No.6I-0593 and tighten to a torque of 55Nm +/- 10Nm. |
|
| Image1.5.1 |
| 4.0 LEAK OFF PIPE ASSEMBLY. 4.1 Assemble 311-1677 leak off pipe (13 plate oil cooler) or 311-1675 (17 plate oil cooler) in the position shown below. Connect the quick connector to the fuel pump leak off spigot (1), connect the quick connector to the filter bleed spigot (2) and assemble the steel leak off pipe (3) in the following way - assemble the steel injector leak off pipe to the pressure relief valve in the fuel rail (3 image 1.6.1)using the nut and olive from the new 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. Ensuring the body of the fitting doesn?t move (using an open ended spanner) tighten the nut to a torque of 26Nm +/- 4Nm for a steel fitting or 21Nm +/- 4Nm for a brass fitting. If the original fitting in the fuel rail is damaged then replace it, otherwise just use the nut and olive from the new fitting. Press the pipes into the three clips indicated. Clip 311-1919 bracket (4) onto the pipe next to the tee on the horizontal leg as shown below. |
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| Image1.6.1 |
| 5.0 STEEL PIPE ASSEMBLY. Care must be taken to ensure part cleanliness ? do not remove protective caps until the part is to be fitted 5.1 Assemble 311-1721 steel pipe as shown below. Locate both compression fittings as far as possible onto the filter outlet and pump inlet spigots. Tighten all four nuts (two on each compression fitting) to a torque of either 26Nm +/- 4Nm for steel fittings or 21Nm +/- 4Nm for brass fittings. (equivalent to 1 1/4 turns) NOTE: Where a compression fitting has already been assembled to a spigot, the assembly procedure is modified ? tighten the nut until a sharp rise in torque is felt then tighten an additional 1/6 to 1/3 turns to seal. A special tool such as a bent spanner will be required on the lower fitting as access is limited. Adhere to cleanliness guidelines at all times. |
|
| Image1.7.1 |
| 6.0 ECM TO SECONDARY FILTER PIPE ASSEMBLY. 6.1 Assemble 311-1331 pipe assembly (13 plate oil cooler) or 311-1293 (17 plate oil cooler) in the position shown below. Connect the quick connector to the ECM spigot (1), connect the quick connector to the secondary fuel filter inlet spigot (2), attach 234-3063 pipe clip (3) and clip pipe onto brackets where indicated below. |
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| Image1.8.1 |
| 7.0 PRIMARY FILTER ASSEMBLY. 7.1 Offer up the original primary fuel filter to the filter bracket as shown below. Ensure that the pipe clip bracket (1) is fitted between the bolt head and the filter head mounting hole on the LEFT hand side. Fit the filter head mounting bolts and tighten to a torque of 55Nm +/- 10Nm. Reconnect pipe (2) from the primary filter to the fuel transfer pump as shown. |
|
| Image1.9.1 |
| 8.0 PROTECTIVE COVER ASSEMBLY. 8.1 Fit new 319-7344 Protective Cover Assembly as shown - Not required for engine reworks in Groups 1 & 4. |
|
| Image1.10.1 |
| 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. |
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