PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTRATION SYSTEM ON CERTAIN C6.6 ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTRATION SYSTEM ON CERTAIN C6.6 ENGINES

Usage:

REBE4395-00

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12Nov2008

U-573

A-476

D-489

O-526

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REWORKING THE FUEL FILTRATION SYSTEM ON CERTAIN C6.6 ENGINES
1251 1258 1261 1262 1263 1290		PS42829

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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 "PS42829" 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

30Nov2011

PROBLEM

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There have been isolated instances of accelerated wear on the electronic unit injectors caused by debris in the fuel. The fuel filter rework will remove the debris and prevent the accelerated injector wear.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C4.4	44400002, 6, 10-11, 13, 17, 19, 22-25, 31, 33-35, 39, 41-46, 48-53, 57, 60-61, 63, 68-70, 79-80, 85-87, 91-92, 99, 101-106, 109-114, 117, 119, 121-123, 125, 128-130, 136, 142, 145, 148-150, 152, 155, 157-158, 160, 164, 169, 172-173, 175, 178, 180-181, 183, 188-190, 193-198, 200, 202-203, 206, 208-210, 212, 216-217, 226, 233-234, 241-242, 245-247, 249-251, 254-255, 259, 264, 267, 269-270, 274, 280, 285-286, 291, 302-303, 305, 307-309, 311-313, 315-316, 318-319, 322-333

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*******Group 2*******

C6.6 TIER 3

66600756, 760-761, 763, 768, 774, 776, 779, 782, 784-786, 830, 834, 837, 839-842, 864, 866-868, 914-917, 987, 990-991, 993-994, 996, 1000, 1003, 1396, 2013-2017, 2021-2022, 2109, 2113, 2128, 2130, 2134, 2151, 2154, 2162-2163, 2356, 2359-2360, 2374, 2376-2377, 2379, 2381, 2384-2385, 2387, 2413, 2415-2416, 2418, 2420, 2492, 2498, 2501-2502, 2504-2505, 2514, 2653-2655, 2657, 2659-2661, 2703, 2705, 2711, 2718-2723, 2827, 2830, 2833-2834, 2836-2838, 2840-2841, 2887-2888, 2890-2896, 2898, 2903, 2905-2906, 2910, 2913-2914, 2916, 2933-2935, 2937, 2977-2979, 2982, 3018-3019, 3055-3056, 3068

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*****Group 3*****
C6.6 TIER 3	66600823, 1399-1400, 1758, 1897, 2033, 2072-2073, 2075-2084, 2086-2088, 2123, 2207-2209, 2221, 2223-2225, 2232-2233, 2236, 2241, 2281, 2294-2295, 2324-2326, 2328, 2366, 2392-2393, 2429, 2451, 2490, 2494, 2496, 2510, 2540-2544, 2567, 2607-2613, 2627, 2644-2647, 2686, 2688, 2697, 2699, 2708, 2740, 2757, 2779, 2783, 2940-2941, 2943-2946, 2961-2962, 3074

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*******Group 4*******

C6.6 TIER 3

66600216, 330, 432-433, 435-436, 444-450, 452, 454-455, 488-489, 492, 496, 507-511, 629, 653-654, 656-658, 662-663, 712, 753, 895-898, 945-948, 951-952, 954, 956, 958, 961, 1005-1011, 1016-1018, 1049, 1052, 1069, 1071, 1073-1075, 1092, 1094-1095, 1101-1103, 1105-1106, 1156-1157, 1160, 1169, 1171-1172, 1178, 1202-1203, 1205, 1226, 1228-1230, 1233-1239, 1241-1242, 1329-1330, 1349-1351, 1363-1365, 1367-1369, 1372-1373, 1395, 1453-1454, 1468, 1471, 1492, 1527, 1529-1533, 1610, 1659-1667, 1670-1678, 1681, 1683-1684, 1688, 1692, 1736, 1755-1756, 1762, 1802-1803, 1877, 1889, 1898, 1979, 2068-2070, 2124-2125, 2143-2145, 2148, 2172, 2194, 2211, 2215, 2237, 2240, 2242-2245, 2249-2252, 2265, 2267-2271, 2273, 2283-2284, 2286, 2288, 2361, 2477-2481, 2483, 2497, 2506-2507, 2518-2519, 2523-2526, 2528, 2530-2537, 2568-2575, 2577-2585, 2619, 2671, 2673-2674, 2709, 2732, 2741-2742, 2745-2747, 2750, 2755, 2760-2763, 2771, 2775-2778, 2806-2808, 2843, 2849-2853, 2856-2859, 2861-2869, 2871, 2930, 2949-2950, 2952, 2954, 2956-2958, 3006-3016, 3020-3029, 3050-3051, 3060, 3066-3067, 3080-3083, 3113-3117, 3123-3133, 3138-3141, 3262, 3345, 3404, 3414-3425

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*****Group 5*****
C6.6 TIER 3	66600920-00921, 1056-1060, 1245-1248, 1251-1254, 1259, 1276-1280, 1305, 1308, 1313-1314, 1878, 1899-1900, 2036-2037, 2039, 2041-2046, 2048, 2052-2064, 2066, 2115-2116, 2118-2122, 2126-2127, 2199, 2201, 2205, 2278, 2317-2319, 2321-2323, 2329, 2331-2334, 2340-2344, 2346, 2349-2350, 2587-2594, 2615-2618, 2997-3003, 3149-3150, 3152-3155, 3239-3248, 3250-3251, 3369-3370, 3372-3376

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*****Group 6*****
C6.6 TIER 3	66600356, 514, 1430, 1434, 1522-1525, 2621, 2623-2625, 2629-2631, 2633-2639, 2725-2730, 2764-2766, 2768-2770, 2773-2774, 2782, 2784-2787, 2789, 2791-2792, 2794-2799, 2983, 2985-2989, 3235-3236, 3280, 3340

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*******Group 7*******

C6.6 TIER 3

66600406-00407, 410, 415, 417, 419, 422, 426-429, 460, 462, 467, 475, 477, 479, 481, 483-484, 528-529, 532, 543, 551, 554, 557, 560-561, 563-564, 568, 571-573, 575, 578, 583, 586-587, 593-594, 603-607, 609, 611, 613, 635, 638-639, 647, 649, 679, 681-682, 684-685, 687, 691-692, 697, 700-701, 705, 708-710, 716, 718, 749, 814-816, 818-819, 826, 828, 845, 850-851, 853-854, 879, 881-882, 899, 904, 907, 911-913, 922, 938-941, 944, 965, 968, 972-973, 975, 986, 1041-1044, 1112-1113, 1133, 1135, 1141-1143, 1145, 1179-1182, 1266, 1282, 1290, 1292, 1315, 1328, 1339, 1357, 1359, 1377-1378, 1381-1388, 1403, 1419-1421, 1426-1427, 1429, 1432, 1438-1439, 1441, 1445, 1447-1448, 1450-1452, 1474-1479, 1482, 1484, 1486-1487, 1494, 1496-1499, 1503, 1506, 1508-1509, 1515-1516, 1521, 1534, 1544-1545, 1547-1548, 1551-1553, 1555, 1557, 1559, 1561-1562, 1565-1566, 1569, 1572, 1574-1575, 1578, 1582-1583, 1587, 1592-1593, 1595, 1597, 1601, 1605, 1608, 1614, 1619-1620, 1626-1627, 1634-1635, 1637, 1643, 1646, 1651-1658, 1696, 1699-1711, 1714, 1716-1728, 1733-1735, 1737, 1739-1741, 1743, 1745, 1748-1749, 1757, 1761, 1763-1764, 1766, 1768-1772, 1774, 1777-1778, 1781, 1784-1791, 1794-1796, 1799, 1801, 1804, 1813, 1817, 1821, 1823, 1826-1827, 1829-1831, 1833-1834, 1836, 1838, 1840, 1842-1845, 1847-1849, 1855, 1857-1859, 1862-1864, 1866-1867, 1882-1883, 1885-1886, 1905-1906, 1909, 1912-1915, 1917-1918, 1921-1924, 1931, 1933-1936, 1939, 1941-1944, 1946, 1951, 1954, 1957, 1960-1961, 1964-1965, 1969, 1971, 1974-1976, 1983-1984, 1986-1987, 1989, 1991-1994, 1996-1997, 2000, 2005, 2007, 2090-2091, 2094-2096, 2098, 2102, 2137, 2181-2192, 2260, 2262, 2289-2290, 2296-2298, 2300, 2303-2304, 2307, 2313, 2336-2338, 2352, 2362, 2364-2365, 2368-2370, 2389-2391, 2394-2397, 2399-2403, 2405-2406, 2421-2423, 2425-2426, 2428, 2432-2438, 2442, 2456-2457, 2459-2464, 2466-2467, 2488, 2595-2606, 2648, 2662-2663, 2665-2666, 2670, 2680, 2875, 2879, 2881, 2883-2884, 2923, 2995-2996, 3086, 3095-3096, 3112, 3157, 3159, 3162-3166, 3177, 3179, 3213-3224, 3377, 3405, 3426-3427, 3431, 3433, 3436, 3439, 3445, 3450, 3453, 3458, 3539, 3542-3543, 3549-3551, 3553, 3557-3563, 3565-3566, 3600, 3608-3611, 3613-3614, 3616-3619

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*****Group 8*****
C6.6 TIER 3	66601890, 2108, 2227, 2409-2412, 2508, 2736, 3119, 3322-3329, 3537

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	6I0254	BOLT
1	2784138	PROTECTION KT
1	3112270	SPACER
1	3112376	FILTER AS
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*****
1	2784138	PROTECTION KT
1	3096653	FILTER AS-FUEL
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*****
1	2784138	PROTECTION KT
1	3090860	FILTER AS-FUEL
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*****
1	2784138	PROTECTION KT
1	3090860	FILTER AS-FUEL
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 5*****
4	1P4278	CLAMP-HOSE
500	5P1420	HOSE (BULK - APPROXIMATELY 500 CM NEEDED)
4	2159513	CONNECTOR-SPL
4	2159515	CONNECTOR-SPL
1	2784138	PROTECTION KT
1	3090860	FILTER AS-FUEL
1	3137111	FILTER AS-F(SEC)
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 6*****
4	1P4278	CLAMP-HOSE
500	5P1420	HOSE (BULK - APPROXIMATELY 500 CM NEEDED)
2	6I0260	BOLT
2	6I0593	BOLT
4	2159513	CONNECTOR-SPL
4	2159515	CONNECTOR-SPL
1	2776165	CONNECTION-FUEL
1	2784138	PROTECTION KT
1	3087480	FILTER AS-FUEL
1	3111110	FILTER AS-FUEL
1	3111175	TUBE-LEAK OFF
1	3111666	BRACKET
1	3111684	TUBE
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 7*****
2	6I0260	BOLT
2	6I0593	BOLT
2	2343063	CLIP
1	2776165	CONNECTION-FUEL
1	2784138	PROTECTION KT
1	3087480	FILTER AS-FUEL
1	3111159	TUBE FILTER-FUEL
1	3111175	TUBE-LEAK OFF
1	3111666	BRACKET
1	3111684	TUBE
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 8*****
2	6I0260	BOLT
2	6I0593	BOLT
2	2343063	CLIP
1	2776165	CONNECTION-FUEL
1	2784138	PROTECTION KT
1	3087480	FILTER AS-FUEL
1	3111166	TUBE - LEAK OFF
1	3111288	TUBE FILTER-FUEL
1	3111666	BRACKET
1	3111684	TUBE
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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When carrying out this service letter you will be advised to perform a "High Leakoff Test" to determine the condition of the electronic unit injectors - to perform this test refer to Special Instruction KENR6938.

Common rail fuel technology requires a high degree of cleanliness. It is therefore imperative to adhere to all cleanliness requirements within this Rework Procedure, 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 must be capped with new clean caps to prevent dirt ingress - 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.

No attempt should be made to clean or flush the filter elements for re-use. Do not pre-fill the filters.

Perform the fuel filter rework as listed in the applicable Special Instructions:

Group 1 (C4.4) Special Instruction REHS3730
Group 2 (C6.6) Special Instruction REHS3731
Group 3 (C6.6) Special Instruction REHS3734
Group 4 (C6.6) Special Instruction REHS3735
Group 5 (C6.6) Special Instruction REHS3736
Group 6 (C6.6) Special Instruction REHS3733
Group 7 (C6.6) Special Instruction REHS3729
Group 8 (C6.6) Special Instruction REHS3732

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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%
*****Group 1*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 1
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.

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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%
*****Group 2*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 2
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.

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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%
*****Group 3*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 3
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.

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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%
*****Group 4*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 4
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.

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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%
*****Group 5*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 5
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.

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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%
*****Group 6*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 6
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.

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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%
*****Group 7*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 7
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.

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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%
*****Group 8*****
0-3000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.5-hour job for Group 8
Included in this 2.5 hour allowance: 1.5 hr to perform 'High Leak Off Test' - KENR6938 1.0 hr to rework the fuel filtration system.