PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SUPPLY AND RETURN FUEL HOSES, CHANGING THE HOSE CLIPPING STRATEGY, REPLACING THE FUEL MANIFOLD, AND CHANGING THE HOSE ROUTING ON CERTAIN C27 AND C32 INDUSTRIAL ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SUPPLY AND RETURN FUEL HOSES, CHANGING THE HOSE CLIPPING STRATEGY, REPLACING THE FUEL MANIFOLD, AND CHANGING THE HOSE ROUTING ON CERTAIN C27 AND C32 INDUSTRIAL ENGINES

Usage:

REBE4041-01

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09Sep2008

(Revised 10Dec2008)

U-460

A-374

D-381

O-421

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SUPPLY AND RETURN FUEL HOSES, CHANGING THE HOSE CLIPPING STRATEGY, REPLACING THE FUEL MANIFOLD, AND CHANGING THE HOSE ROUTING ON CERTAIN C27 AND C32 INDUSTRIAL ENGINES
1274		PI31555

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31555" 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 "PI31555" 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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NOTE:	This Revised Service Letter replaces the 09Sep2008 Service Letter. Changes have been made to Parts Needed and Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31Mar2009	30Sep2009

PROBLEM

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The fuel hoses, port connectors, fuel manifold and p-clips need to be reworked on certain C27 and C32 industrial engines. The existing clipping strategy can cause undesirable hose wear, which can result in hose failure. Pressure spikes from the injectors may also cause the existing hoses to fail. Problems have also been identified with cavitation in the fittings on the fuel hoses on the front and rear of the engine. This service letter calls for shorter port connectors, additional clipping and fuel lines with straight fittings to eliminate these problems.

Failure of these components or failure to properly apply this service letter could cause fuel leaks. Fully read and understand all details of this service letter before performing this rework.

AFFECTED PRODUCT

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Model	Identification Number
C27	TWM00101-00979
C32	TLD00100-00371

PARTS NEEDED

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Qty	Part Number	Description
2	0S1588	BOLT
1	0S1590	BOLT
1	0S1591	BOLT
2	0S1594	BOLT
2	0S1619	BOLT
1	1A2029	BOLT
4	1P1376	CONNECTOR-STOR
1	1P3381	BRACKET
1	2R6806	CONNECTOR
3	3B1915	BOLT
1	3K1470	SPACER
12	5M2894	WASHER-HARD
2	5P7462	CLIP
2	5P7463	CLIP
1	5P8244	WASHER-HARD
2	6L2479	BRACE
2	6V0683	GROMMET
6	7V6571	GROMMET
2	8L2786	SEAL-O-RING
3	8S9191	BOLT
6	8T1889	CLIP-2 PIECE
6	8T1890	CLIP-2 PIECE
1	8T9382	BOLT
1	9S8005	PLUG-O-RING
10	9S8752	NUT-FULL
240	9X2374	HOSE (BULK - Inches) (As Required )
11	9X6458	WASHER-HARD
1	0054362	ELBOW
1	0307937	CONNECTOR-PORT
2	0908635	SPACER
1	1275447	SPACER
6	2147568	SEAL-O-RING-STOR
1	2284064	BRACKET
1	2287381	VALVE GP-CHECK-A
7	2751442	CLIP
7	2751443	CLIP
7	2751444	GROMMET
1	2999606	PLATE AS.
1	3143173	MANIFOLD
1	3143174	BRACKET AS
1	3227615	HOSE AS.
2	3227616	HOSE AS.
1	3227617	HOSE AS.
1	3267471	BRACKET
1	3267472	BRACKET
1	3286200	BRACKET
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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Refer to the attached Rework Procedure to complete service letter. Take photos of the new fuel hose routing at each corner of the engine once the rework procedure has been completed. Attach the image files to the SIMSi entry.

Use the following images in the Rework Procedure as reference when taking photos to be attached to the SIMSi entry.

Image 1.8.2
Image 1.9.1
Image 1.11.2
Image 1.12.2
Image 1.13.1

NOTE: Do not use Caterpillar HIS information to fabricate the 322-7615, 322-7616, and 322-7617 Hoses. These hoses must be purchased from the Caterpillar Parts System as complete assemblies.

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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 5.0-hour job
NOTE: Attach pictures described in Action Required to the SIMSi entry.

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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 SUPPLY AND RETURN FUEL HOSES, CHANGING THE HOSE CLIPPING STRATEGY, REPLACING THE FUEL MANIFOLD AND CHANGING THE HOSE ROUTING ON CERTAIN C27 AND C32 INDUSTRIAL ENGINES

MODELS INVOLVED - C27 and C32 Industrial Engines

Dear Caterpillar Product Owner:

The fuel hoses, port connectors, fuel manifold, and p-clips need to be reworked on the products listed below. The existing clipping strategy can cause undesirable hose wear, which can result in hose failure. Pressure spikes from the injectors may also cause the existing hoses to fail. Problems have also been identified with cavitation in the fittings on the fuel hoses on the front and rear of the engine. This service letter calls for shorter port connectors, additional clipping, and fuel lines with straight fittings to eliminate these problems. 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 09Sep2008 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 09Sep2008 Service Letter

Rework Procedure

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NOTE: Some fuel filter installations have been modified from the "As Shipped" fuel filter installation and may require a variation of hose routings to complete this rework procedure. Use the following guidelines to update the additional lengths of hoses needed if the fuel filters have been relocated to the left hand side of the engine, or to locations that differ from the "As Shipped" configuration.

- The (1) 322-7615, (2) 322-7616, and (1) 322-7617 Hoses for engine supply and return to the head shall be purchased from the Caterpillar parts distribution system as specified in this Rework Procedure. These hoses cannot be built, and must be ordered through the Caterpillar parts distribution system. The routing and clipping of these hoses should not differ from the instructions stated in this Rework Procedure. No modifications to the routing and clipping of these hoses is allowed.

Care should be taken that any other modifications to different hoses or clipping locations does not allow these hoses to touch or rub against any other components except the rubber grommetted clips.

- All hoses to and from the fuel filters shall be constructed of 9X-2374 bulk hose. These hoses shall be properly routed and supported with rubberized grommets. 275-1442 clips, 275-1443 clips, and 275-1444 grommets should be used for securing two hoses. 5P-7462 clips and 6V-0683 grommets should be used for securing a single hose. Spacing of the clips and grommets are critical to assure hoses do not lie on each other or rub against other equipment. Ideal distance between clips is 16 inches.

- There are no specific requirements for selection of fittings or couplings. Please refer to the Caterpillar hose guide or reference 001-6287 and 068-0556 couplings for connection fittings.

- No cable tie fastening is allowed.

NOTE: Do not use Caterpillar HIS information to fabricate the 322-7615, 322-7616, and 322-7617 Hoses. These hoses must be purchased from the Caterpillar Parts Distribution System as complete assemblies.

1. Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated. Use caution to ensure that no dirt enters the fuel port in the cylinder head. Damage to the fuel injectors could result.

2. Loosen fittings on the cylinder heads for both the front and rear supply and return hoses (1) and drain fuel into appropriate container. Remove old hoses and P-clips. (Do not reuse the hoses and P-clips). If the old hoses are damaged, determine the source of the damage and correct when installing the new hoses.

Image1.2.1

3. Remove four existing port connectors from the cylinder heads and replace with new 1P-1376 connectors and 214-7568 o-ring seals. Tighten the connectors to 34 +/- 3 N*m (25 +/- 2 lb ft). Wait to install new rear hoses until the 314-3173 steel manifold and the four hoses going to/from the primary and secondary fuel filters are properly installed and oriented.

Image1.3.1

4. Remove existing rear fuel manifold and bracket and replace with 314-3173 steel manifold and 299-9606 bracket. Use three 8S-9191 bolts and three 9X-6458 washers to secure the bracket to the inlet manifold. Use two 0S-1619 bolts, two 5M-2894 washers, and two 9S-8752 nuts to secure the manifold to the bracket. Install 005-4362 elbow using a 8L-2786 O-ring. Install one 2R-6806 connector using one 214-7568 O-ring seal in the 314-3173 steel manifold for the left hand side. Install one 030-7937 connector using one 214-7568 O-ring seal in the 314-3173 steel manifold for the right hand side.

NOTE: It is important to install this 030-7937 connector on right hand side to provide adequate clearance for this return hose to clear hoses running to/from the fuel filters.

Install 228-7381 check valve group and 9S-8005 plug with 8L-2786 O-ring seal.

Image1.4.1

5. Rotate fittings approximately thirty degrees on transfer pump outlet and 314-3173 steel manifold (2) to return-to-tank hose. Connect existing hose to 005-4362 elbow mounted on the 314-3173 steel manifold.

Image1.5.1

6. Remove existing clipping (four locations) (3) for the hoses routed to/from the primary and secondary fuel filters. Also cut existing tie straps and remove existing ladder clip (4) on right rear of engine.

Image1.6.1

Image1.6.2

7. Install new 326-7472 bracket on third set of inlet manifold bolts using the original inlet manifold bolts.

Image1.7.1

8. Refer to Images 1.8.1 and 1.8.2 with hose labels for routing purposes.

(1) - Steel manifold to return-to-tank hose
(2) - Pump outlet to secondary fuel filter hose
(3) - Primary fuel filter to pump inlet hose
(4) - Secondary fuel filter to Electronic Control Module (ECM) hose

Image1.8.1

Image1.8.2

9. Install rubber grommeted clips in order as indicated below.

NOTE: Installation order is very critical to assure excess slack is kept near primary and secondary filters. Perform installation in the order specified in A through D. Refer to Image 1.9.1 for A through D.

- A. Install new rubber grommeted clip (5) for steel manifold to return-to-tank hose on 326-7472 bracket (from Step 7) using a 5P-7462 clip, a 5P-7463 clip, and a 6V-0683 rubber grommet. Opening in the grommet must line up between gap in the 5P-7462 and 5P-7463 clips. Secure to 326-7472 bracket with a 1A-2029 bolt, two 5M-2894 washers and a 9S-8752 nut.

- B. Install double grommeted clip (6) on 326-7472 bracket using a 275-1442 clip, a 275-1443 clip and a 275-1444 rubber grommet. Secure to 326-7472 bracket with a 0S-1594 bolt, two 5M-2894 washers and a 9S-8752 nut.

- C. Install new rubber grommeted clip (7) for secondary fuel filter to ECM hose using a 326-7471 bracket, a 5P-7462 clip, a 5P-7463 clip and a 6V-0683 rubber grommet. Opening in the grommet must line up between gap in the 5P-7462 and 5P-7463 clips. The 326-7471 bracket attaches to the upper right hand bolt on the right rear valve cover. Use existing valve cover bolt to secure the bracket. Secure the two piece clip to 326-7471 bracket using a 0S-1588 bolt, two 5M-2894 washers and a 9S-8752 nut.

- D. Install remaining 3 double grommeted clips (8) working from the top of the engine down toward the primary and secondary fuel filters using two 275-1442 clips, two 275-1443 clips and two 275-1444 rubber grommets at each of the 3 locations. To secure the 3 double grommeted clips to the brackets, use a 3B-1915 bolt, a 5M-2894 washer on the bolt head side, a 9X-6458 washer on the nut side and a 9S-8752 nut at each of the 3 locations.

The first double grommeted clip closest to the fuel transfer pump uses a 1P-3381 bracket to offset the double grommeted clip. Units with a 234-5913 ladder casting bracket need to use a 9X-6458 washer so the chamfer in the ladder casting is accounted for. Units without the 234-5913 ladder casting do not need this 9X-6458 washer.

The second double grommeted clip uses a 228-4064 bracket that replaces the existing bracket mounted on the rear housing. The third double grommeted clip uses the existing 4P-7048 bracket.

Once the installation of the hose is complete, review the work to be sure the entire routing is correct with the hose only touching the rubber grommet in the P-clip. Adjust if required.

Image1.9.1

10. Rework of the right rear fuel hose:

- Connect the 322-7617 fuel hose to the 030-7937 port connector and the 314-3173 fuel manifold and tighten both ends to 27 +/- 6 N*m (20 +/- 4 lb ft).

NOTE: Make sure 030-7937 port connector is in place to provide adequate clearance for hoses running to/from the fuel filters.

Note: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure.

Once hose is secure, install a new 7V-6571 rubber grommet using an 8T-1889 and 8T-1890 two-piece clip mounted with a 328-6200 bracket. Install clip mounted upward as shown in the Images 1.10.1 and 1.10.2. Opening in the grommet must line up between gap in the 8T-1889 and 8T-1890 clips. Use two 090-8635 spacers, two 9X-6458 washers, one 0S-1588 bolt and one 9S-8752 nut to properly mount the two-piece rubber grommeted clip.

If unit has a ladder casting, be sure the fuel hose routes through the opening without touching it. Once the installation of the hose is complete, review the work to be sure the entire routing is correct with the hose only touching the rubber grommet in the P-clip. Adjust if required. Refer to Images 1.10.1 and 1.10.2.

Image1.10.1

Image1.10.2

11. Rework of the left rear fuel hose:

? While the existing P-clip is removed, replace existing stud with bolt and washer located in the original P-clip hole (9). Connect the 322-7615 fuel hose to the port connector and the 314-3173 fuel manifold and tighten both ends to 27 +/- 6 N*m (20 +/- 4 lb ft).

Note: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure.

Install new 7V-6571 rubber grommet using an 8T-1889 and 8T-1890 two-piece clip mounted with a 314-3174 bracket. Opening in the grommet must line up between gap in the 8T-1889 and 8T-1890 clips. Install a 127-5447 spacer in original P-clip hole using one 9X-6458 washer, one 0S-1590 bolt, one 5P-8244 washer and one 8T-9382 bolt to properly mount the two-piece rubber grommeted clip (10).

Once the installation of the hose is complete, review the work to be sure the entire routing is correct with the hose only touching the rubber grommet in the P-clip. Adjust if required. Refer to Images 1.11.1 and 1.11.2.

Image1.11.1

Image1.11.2

12. Rework of the right front fuel hose:

? Connect the 322-7616 fuel hose to the port connector and the tee and tighten both ends to 27 +/- 6 N*m (20 +/- 4 lb ft).

NOTE: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure.

Remove existing steel block (11) and install a new 6L-2479 brace using the existing bolt and washer. The existing steel block (11) should be remounted to complete assembly. Install new 7V-6571 rubber grommet, 8T-1889 two-piece clip, and a 8T-1890 two-piece clip. Install second rubber grommeted clip on front right side using a 7V-6571 rubber grommet, 8T-1889 two-piece clip, and a 8T-1890 two-piece clip. Opening in the grommet must line up between gap in the 8T-1889 and 8T-1890 clips. Use existing spacer (12) to ensure adequate spacing. Secure with existing bolt and washer. When properly installed, this hose will have two clips securing it.

Image1.12.1

Image1.12.2

13. Rework of the left front fuel hose:

? Connect the 322-7616 fuel hose to the port connector and the tee and tighten both ends to 27 +/- 6 N*m (20 +/- 4 ft-lb).

Note: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure.

Install a new 6L-2479 brace with existing bolt and washer. Use a 3K-1470 spacer (13), a 0S-1591 bolt, two 5M-2894 washers, and a 9S-8752 nut to install the rubber grommeted clip. This 3K-1470 spacer has to be used to ensure proper routing of the house. Install new 7V-6571 rubber grommet, 8T-1889 two-piece clip and a 8T-1890 two-piece clip and tighten. Install second rubber grommeted clip on front left side using a 7V-6571 rubber grommet, 8T-1889 two-piece clip, and a 8T-1890 two-piece clip. A 0S-1594 bolt and 9X-6458 washer should be used to fasten the two-piece clip. Opening in the grommet must line up between gap in the 8T-1889 and 8T-1890 clips. When properly installed, this hose will have two clips securing it.