PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW FUEL FILTRATION SYSTEM ON CERTAIN C6.6 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW FUEL FILTRATION SYSTEM ON CERTAIN C6.6 ENGINES

Usage:

REBE4556-00

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17Feb2009

U-69

A-59

O-58

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A NEW FUEL FILTRATION SYSTEM ON CERTAIN C6.6 ENGINES
1262 1258 1261 1263		PI31633

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31633" 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 "PI31633" 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:

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COMPLETION DATE	TERMINATION DATE
31Aug2009	28Feb2010

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

C6.6 TIER 3

66600753, 822, 1212-1223, 1455-1466, 1868-1877, 1962-1963, 2167-2171, 2174-2180, 2696, 2800-2805, 3137-3141, 3146, 3262, 3390-3401, 3775-3780, 3823, 3844-3849, 4318, 4462-4467, 4539, 4545-4549, 4716, 4816-4819, 5317-5322, 5379-5380, 5405-5410, 5438-5440, 5530-5535, 5608-5617, 5665, 6669-6678, 7357-7358, 7540, 7759-7764, 7785-7790, 7842-7843, 7908-7909, 7969-7970, 8392, 8429-8430, 8616-8617, 8877-8882

PARTS NEEDED

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Qty	Part Number	Description
2	6I0593	BOLT
2	6I0594	NUT
1	2123657	PUMP GP-F PRM&-A
1	2280172	FITTING-FUEL
1	2343063	CLIP
1	2776165	CONNECTION-FUEL
1	3087480	FILTER AS-FUEL
1	3111110	FILTER AS-FUEL
1	3111677	TUBE-LEAK OFF
1	3111721	TUBE PUMP-FILTER
1	3111737	BRACKET AS
1	3111919	BRACKET AS
1	3197348	BRACKET AS-SPRT
1	3357051	BRACKET
1	10083568	Installation Kit (See Action Req. for ordering)
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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Install new fuel filtration system.

Refer to the attached Rework Procedure.

NOTE: Prior to Starting any Rework Please Note.

The 10083568 Kit contains additional parts that need to be purchased directly from Forest Products North (FPN), Zebulon, NC. These additional lines and brackets need to be purchased to complete the update. For each machine which will be updated, please order the appropriate kit below:

Model 559 ? order kit number 10083568 (line and bracket kit only)

If you have additional questions, please contact your local FPN Field Service Representative; or call the Caterpillar Forestry Products technical help desk:

Within U.S.: 1-800-798-4082
Outside U.S.: 919-269-7421

Cat Forestry Products
535 Mack Todd Road
Zebulon, NC, 27597

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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 6.0-hour job
NOTE: The breakdown for the 6 hour job, is as follows: - 1.5 hours will be allowed for the diagnostic leak off check - 4.5 hours will be allowed for the addition of the improved fuel filter arrangement. NOTE: If the average results of the three leak off measurement readings are > 50ml/30 seconds, then a future injector failure exists. A high leak off test should initiate a replacement of the fuel system components. If the outcome of the leak off test indicates that a future injector failure exists, it is perfectly acceptable to return the machine into service and to apply the improvement filter arrangement only, and schedule the additional component at a later date. The time and cost for the additional components for the fuel system replacement should be submitted to Caterpillar as a separate warranty claim from the improved filter arrangement. Use the injector part number as the part causing failure.

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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 INSTALLING THE NEW FILTRATION SYSTEM ON CERTAIN C6.6 ENGINES

MODELS INVOLVED - C6.6 Engines

Dear Caterpillar Product Owner:

The fuel filtration system needs to be reworked on the products listed below. The existing fuel filtration system can allow debris to affect other fuel system components. 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 17Feb2009 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 17Feb2009 Service Letter

Rework Procedure

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Important Notes:

- The fuel system is designed to operate using 4 microns filtered fuel and is very sensitive to particle size. It is imperative to adhere to all cleanliness requirements within this Service Letter. 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 LP pipe is removed.
- 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 LP 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 is >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 is <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.

Prior to Starting any Rework Please Note.

- The 10083568 Kit contains additional parts that need to be purchased directly from Forest Products North (FPN), Zebulon, NC. These additional lines and brackets need to be purchased to complete the update. For each machine which will be updated, please order the following kit of parts for machine model 559 ? order kit number 10083568 (line and bracket kit only)

If you have additional questions, please contact your local FPN Field Service Representative or call the CFP technical help desk at 1-800-798-4082.

Warranty reimbursement will cover the parts kits only listed above, and must be filed through the CFG Warranty on-line system.

Image 1.1.1 is a new System Diagram of the Low Pressure (LP) Fuel System:

Image1.1.1

System Fitting:

The 10083568 field retro-fit kit contains:
- 1 Secondary 4 micron fuel filter assembly.
- 1 Tertiary 4 micron fuel filter assembly.
- Fuel filter brackets.
- Nylon fuel pipe (ECM to Secondary fuel filter).
- Nylon and steel fuel pipe (Leak off / Fuel return).
- Steel fuel pipe (Tertiary fuel filter to HP fuel pump inlet).
- Electric primer filter.

The below notes describe the fitting process required for fitting the rework kit. This assumes the machine is already fitted with a two filter LP fuel system.

Removal of existing components

The secondary fuel filter assembly should be removed by disconnecting the 3 quick connectors (1, 2, & 3). Depress the release button and pull pipe off the spigot. Immediately plug the pipes with a new clean plug. Unbolt and remove the 289-2538 Filter Assembly shown in Image 1.2.1

Image1.2.1

Install new 335-7051 Bracket (4) reusing the existing bolts and tighten to a torque of 55 Nm +/- 10 Nm. Assemble the 311-1737 Spacer 2 off to the fuel filter bracket using 2 off 6I-0594 M10 flange nuts (1) .

Assemble the 308-7480 Filter (3) to the mounting bracket using (2) 6V-0593 M10 bolts (5) and tighten to a torque of 55Nm +/- 10Nm. See Image 1.3.1.

Image1.3.1

Leak Off Pipe Assembly

Assemble the 311-1677 Leak Off Pipe to the 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) as follows:
- Assemble the steel injector leak off pipe to the pressure relief valve in the fuel rail (3) using the 277-6165 fuel connection.
- Put the nut then olive onto the pipe end, push the pipe fully into the fitting and tighten the nut by hand.
- Ensure the body of the fitting doesn?t move (using an open ended wrench) and tighten the nut to a torque of 26 Nm +/- 4 Nm for a steel fitting, and tighten to a torque of 21 Nm +/- 4 Nm for brass fittings.(equivalent to 1 1/4 turns).
- Press the pipes into the three clips indicated (5).
- Clip the 311-1919 Bracket (4) onto the pipe next to the tee on the horizontal leg as shown in Fig 1.4.1.

Image1.4.1

Steel Pipe Assembly

Care must be taken to ensure part cleanliness ? do not remove protective caps until the part is to be installed.

Assemble the 311-1721 steel pipe as shown in Image 1.5.1. 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 26 Nm +/- 4 Nm for steel fittings, or 21 Nm +/- 4 Nm 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.

Image1.5.1

There is also a new fuel pump connection available, check which connection is installed and change to the new one if required 228-0172. Refer to Image 1.6.1 for the differences.

Image1.6.1

Primary Filter Assembly

Mount the new 212-3657 Primary Fuel Filter to the filter bracket as shown in Image 1.7.1.
Install the filter head mounting bolts and tighten to a torque of 55 Nm +/- 10 Nm.
Connect the new pipes supplied in FPN kit 10083568 to the primary inlet from the fuel tank and the primary outlet to the transfer pump.

Image1.7.1

Remote Mounted Secondary Filter

Use the new 311-1110 Secondary Fuel Filter, which will be mounted on engine at the mounting foot position, and FPN kit 10083568. This kit includes the required fuel lines and mounting bracket for the secondary filter arrangement.

1. Assembly the 311-1110 Filter to the engine mounting foot using the mounting bracket and 2 mounting bolts supplied in the FPN kit.

2. Connect the required pipe between the ECM and secondary filter.

3. Connect pipe between the secondary filter to tertiary filter using the connectors supplied in the FPN kit. Refer to Image 1.8.1.

Image1.8.1

Part Reference for Image 1.8.1:

6. 304-7047 Cast primary mount
7. 311-1110 Filter head
12. 125646 Connection
13. 125744 Connection
14. 125848 Plug
17. 225496 Connection
18. 226226 Adapter
20. 307022 Bolt
21. 10034461 Connection
23. 10062351 Adapter
24. 10066282 Adapter
26. 10087484 Plate
28. 10087509 Bolt
30. 10087521 Hose
31. 10087522 Hose
32. 10087523 Hose

FINAL ASSEMBLY NOTES

Prime the fuel system as directed in the System Operation Test and Adjustment section ? Fuel system prime.

Check the fuel system for leaks and rectify if required.