PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 235-3362 FUEL PRESSURE REGULATOR ON CERTAIN 3606, 3608, 3612, 3616, C280-6, C280-8, C280-12, AND C280-16 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 235-3362 FUEL PRESSURE REGULATOR ON CERTAIN 3606, 3608, 3612, 3616, C280-6, C280-8, C280-12, AND C280-16 ENGINES

Usage:

REBE3929-00

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07Aug2008

U-409

A-334

D-337

O-373

TM-17

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 235-3362 FUEL PRESSURE REGULATOR ON CERTAIN 3606, 3608, 3612, 3616, C280-6, C280-8, C280-12, AND C280-16 ENGINES
1715		PI31544

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31544" 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 "PI31544" 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
28Feb2009	31Aug2009

PROBLEM

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The internal diaphram may rupture allowing fuel to enter the upper portion of the valve and may allow fuel to leak externally from the adjusting screw and or identification tag rivets.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
3606	8RB00656-00657, 659-660, 724-725, 728-731, 764-767, 809-810
3608	6MC00291-00294, 636-637, 650, 709, 715, 718-719
C280-6	LDL00100-00105
C280-8	NDT00100-00114 PKA00100-00105, 108-113

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*****Group 2*****
3612	9RC00256-00257, 259-260
3616	1PD00216, 218
C280-12	RDW00101-00106 TSJ00100-00103
C280-16	NKB00108-00125 TDX00100-00115, 117-133

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	0L1143	BOLT
1	3P1156	SEAL-O-RING
3	3V3308	WASHER-HARD
1	4B3611	SETSCREW-SQ HEAD
2	4F7957	BOLT
1	4W8082	TUBE AS
2	5P0537	WASHER-HARD
1	5P6416	ELBOW-90 DEG
2	6V1903	SEAL-O-RING
1	7E1704	VALVE
1	7W7725	BODY-VALVE
1	7W7726	PLATE
1	7W7727	RETAINER
1	9K1242	CONNECTOR-FLARED
1	9S4191	PLUG-STOR
1	9S8752	NUT-FULL
1	2147568	SEAL-O-RING-STOR
1	3309050	SPRING
1	3313971	SPACER
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 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	0L1143	BOLT
1	3P1156	SEAL-O-RING
3	3V3308	WASHER-HARD
1	4B3611	SETSCREW-SQ HEAD
2	4F7957	BOLT
2	5P0537	WASHER-HARD
1	5P6416	ELBOW-90 DEG
2	6V1903	SEAL-O-RING
1	7C5778	TUBE AS
1	7E1704	VALVE
1	7J7187	CONNECTOR
1	7W7725	BODY-VALVE
1	7W7726	PLATE
1	7W7727	RETAINER
1	9S4191	PLUG-STOR
1	9S8752	NUT-FULL
1	2147568	SEAL-O-RING-STOR
1	3309050	SPRING
1	3313971	SPACER
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 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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The 235-3362 Fuel Pressure Regulator needs to be replaced on certain 3606, 3608, 3612, 3616, C280-6, C280-8, C280-12, and C280-16 engines.

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 4.0-hour job for Group 1

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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 4.0-hour job for Group 2

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 235-3362 FUEL PRESSURE REGULATOR ON CERTAIN 3606, 3608, 3612, 3616, C280-6, C280-8, C280-12, AND C280-16 ENGINES

MODELS INVOLVED - 3606, 3608, 3612, 3616, C280-6, C280-8, C280-12, and C280-16 Engines

Dear Caterpillar Product Owner:

The 235-3362 Fuel Pressure Regulator needs to be replaced on the products listed below. The existing 235-3362 fuel pressure regulator internal diaphram may rupture and allow fuel to enter into the upper portion of the valve and may allow the fuel to leak externally from the adjusting screw and or identification tag rivets. You will not be charged for the service performed.

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 07Aug2008 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 07Aug2008 Service Letter

Rework Procedure

Group Number 1

For Inline Engines that use the 246-3389 and 246-3390 Lines Group - Fuel Injection.

1. Turn off the fuel supply to the engine.

NOTE:
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

2. Disconnect the fuel lines from the regulator valve and allow the fuel to drain in the proper container.

3. Remove the pressure regulator and mounting bracket as one assembly. Do not reuse.

4. Remove the 5R-0939 and 5R-0940 Clip, Bolt, and washer. These will be reused.

5. Remove the 248-6654 Tube Assembly. Do not reuse.

Installation of new components.

6. Assemble the pressure regulator. Refer to Image 1.1.1.

7. Install the new pressure regulator using two 0L-1143 Bolts and 3V-3308 Washers.

8. Install the 4W-8082 Tube Assembly.

9. Install the 5R-0939 and 5R-0940 Clip, Bolt, and washer that were removed in step (4). Do not tighten at this time.

10. Tighten the 4W-8082 Tube Assembly to a torque of 108 +/- 10 Nm (80 +/- 7 Lb ft).

11. Tighten the 5R-0939 and 5R-0940 Clip, Bolt, and Washer.

12. Install the return line to the pressure regulator.

13. Turn on the fuel supply to the engine.

14. Prime the engine and inspect for leaks.

15. Adjust the fuel pressure regulator setscrew to obtain 820 +/- 20 kPa (119 +/- 3 psi) fuel pressure at rated load and speed.

Image1.1.1

1) 7W-7725 Body, 2) 9K-1242 (inline) 7J-7187 (vee) Connector, 3) 6V-1903 Seal-o-ring, 4) 214-7568 Seal-o-ring, 5) 9S-4191 Plug, 6) 5P-6416 Elbow, 7) 7E-1704 Valve, 8) 330-9050 Spring, 9) 331-3971 Spacer, 10) 3P-1156 Seal-o-ring, 11) 7W-7727 Retainer, 12) 7W-7726 Plate, 13) 5P-0537 Washer, 14) 4F-7957 Bolt, 15) 3V-3308 Washer, 16) 9S-8752 Nut, 17) 4B-3611 Setscrew.

Group Number 2

For Vee Engines that use the 246-3391 and 246-3392 Lines Group - Fuel Injection.

1. Turn off the fuel supply to the engine.

NOTE:
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

2. Disconnect the fuel lines from the regulator valve and allow the fuel to drain in the proper container.

3. Remove the pressure regulator and mounting bracket as one assembly. Do not reuse.

4. Remove the 255-7173 Tube Assembly. Do not reuse.

Installation of new components.

5. Assemble the pressure regulator. Refer to Image 1.1.1.

6. Install the new pressure regulator using two 0L-1143 Bolts and 3V-3308 washers.

7. Install the 7C-5778 Tube Assembly.

8. Tighten the 7C-5778 Tube Assembly to a torque of 135 +/- 13 Nm (100 +/- 10 Lb ft).

9. Install the return line to the pressure regulator.

10. Turn on the fuel supply to the engine.

11. Prime the engine and inspect for leaks.

12. Adjust the fuel pressure regulator setscrew to obtain 820 +/- 20 kPa (119 +/- 3 psi) fuel pressure at rated load and speed.