PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL MANIFOLD (RAIL) ON CERTAIN C6.6 INDUSTRIAL ENGINES AND C6.6 ENGINES INSTALLED IN VARIOUS APPLICATIONS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL MANIFOLD (RAIL) ON CERTAIN C6.6 INDUSTRIAL ENGINES AND C6.6 ENGINES INSTALLED IN VARIOUS APPLICATIONS

Usage:

REBE4824-00

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09Apr2009

U-139

A-122

D-118

O-122

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL MANIFOLD (RAIL) ON CERTAIN C6.6 INDUSTRIAL ENGINES AND C6.6 ENGINES INSTALLED IN VARIOUS APPLICATIONS
1702 1290 1251		PS51647

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51647" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "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

30Apr2010

PROBLEM

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The 3116632/">311-6632 Pressure Relief Valve on the C6.6 Fuel Manifold may leak at the connection with the fuel manifold due to a machining error in the pressure relief valve recess.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C6.6 TIER 3	66609964-09988, 9993-9997, 10024-10082, 10085-10115, 10150-10180, 10182-10193, 10195-10196, 10219-10228, 10230-10273, 10275-10294, 10296-10313, 10317-10326, 10332-10361, 10363-10392, 10394-10395, 10397, 10399-10408, 10411-10427, 10430, 10432, 10434, 10436-10437, 10439-10478, 10480-10520, 10523-10524, 10526, 10528-10530, 10532-10537, 10539-10541, 10543-10560, 10562, 10567-10572, 10579-10590, 10592-10593, 10595, 10598-10601, 10603-10631, 10636-10641, 10657-10659, 10661-10675, 10677-10682, 10684-10688, 10692-10697, 10699-10701, 10705, 10707, 10728-10732, 10734-10741, 10744-10749

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*****Group 2*****
924H	JTM00806-00814 KLN00340-00362
924H Z	PED00584-00650 WLB00244-00271
928H	BYD00386-00393
930H	FTD01027-01108
M316D	W6A01054
M318D	W8P01105 W8R00308-00311
M322D MH	W2T00416-00424

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*****Group 3*****
120M	B9C00446 B9W00182
938H	JKM00648-00705 LKM00281-00449
953D	LBP00912
CP56	FCP00109-00126
CP64	P7F00105
CP76	C7L00107-00110
CS56	FCS00291-00381
CS64	C7F00131
CS74	C8F00229-00263
CS76	CYX00191-00248
D6K LGP	DHA01041-01070
D6K XL	FBH01288-01383
D6N LGP	DJY01552-01639
D6N XL	DJA01126-01177
D6N XL DS	JAH00283-00286
IT38H	JNJ00335-00351
PL61	WGS00144-00163

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2784138	PROTECTION KT
1	2997878	FILM-WARN HAND
1	3116632	RAIL AS-FUEL
1	3368174	TUBE-FUEL INJ 1
1	3368175	TUBE FUEL-INJ 2
1	3368176	TUBE FUEL-INJ 3
1	3368177	TUBE FUEL-INJ 4
1	3368178	TUBE FUEL-INJ 5
1	3368179	TUBE FUEL-INJ 6
1	3368180	TUBE FUEL-INJ
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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	2997878	FILM-WARN HAND
1	3116632	RAIL AS-FUEL
1	3368174	TUBE-FUEL INJ 1
1	3368175	TUBE FUEL-INJ 2
1	3368176	TUBE FUEL-INJ 3
1	3368177	TUBE FUEL-INJ 4
1	3368178	TUBE FUEL-INJ 5
1	3368179	TUBE FUEL-INJ 6
1	3368180	TUBE FUEL-INJ
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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	2997878	FILM-WARN HAND
1	3116632	RAIL AS-FUEL
1	3368174	TUBE-FUEL INJ 1
1	3368175	TUBE FUEL-INJ 2
1	3368176	TUBE FUEL-INJ 3
1	3368177	TUBE FUEL-INJ 4
1	3368178	TUBE FUEL-INJ 5
1	3368179	TUBE FUEL-INJ 6
1	3368180	TUBE FUEL-INJ
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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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Replace the 3116632/">311-6632 Fuel Manifold with a new part of the same part number if a leak is reported at the pressure relief valve connection.

Refer to appropriate service manuals as necessary.

Rework Procedure:

1. Remove machine parts as necessary to gain sufficient access to the engine.

2. Remove failed 3116632/">311-6632 Fuel Manifold and replace with a new part of the same part number. Refer to the appropriate Assembly & Disassembly Instruction "Fuel manifold(rail)- Remove & Install".

3. Fit the 299-7878 Label (Film-Warn Hand) to the new 3116632/">311-6632 Fuel Manifold in the same location that is was located on the part that was removed.

4. Install all parts that were removed to gain access to the engine.

5. Check for leaks and repair as necessary.

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Image1

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*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 1.5-hour job for Group 1

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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*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 2

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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*****
0-2000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%