PRODUCT SUPPORT PROGRAM FOR FITTING A MODIFIED FUEL FILTER ARRANGEMENT TO CERTAIN C6.6 ENGINES IN ROCKDRILL APPLICATIONS Caterpillar

PRODUCT SUPPORT PROGRAM FOR FITTING A MODIFIED FUEL FILTER ARRANGEMENT TO CERTAIN C6.6 ENGINES IN ROCKDRILL APPLICATIONS

Usage:

REBE1369-00

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24Oct2006

U-690

A-666

D-651

O-673

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR FITTING A MODIFIED FUEL FILTER ARRANGEMENT TO CERTAIN C6.6 ENGINES IN ROCKDRILL APPLICATIONS
1262 1258 1261 1263		PS42274

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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 "PS42274" 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

31Oct2008

PROBLEM

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High contamination of debris in the fuel from the environment that the machines are working in causing accelerated wear on the injectors.

AFFECTED PRODUCT

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Model	Identification Number
C6.6 Tier 3	66600211-00212, 236-238, 240-246, 277-291, 293-304, 320-328, 334-338, 344-350, 354-355, 357-363, 374, 429, 513, 515-519, 604-605, 630-634, 664-666, 668-675, 714-718, 724-727, 729-733, 735-739, 741, 749-752, 797-798, 800-801, 803-804, 807-818, 885-886, 890, 893, 1021-1024, 1026-1029, 1034-1038, 1041-1044, 1115-1117, 1121-1124, 1126, 1128, 1184-1194

PARTS NEEDED

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Qty	Part Number	Description
2	1004830	BOLT
1	1192978	BASE AS.-F FLTR
3	1243815	BOLT
1	1832823	PUMP AS-F PRM
1	1P0436	GASKET-PR PUMP
1	1R0751	FILTER AS-FUEL
1	1R0770	FILTER AS-SEP
1	2029871	BASE AS.
1	2705320	BOWL AS-FWS
1	2A1371	BOLT
1	3030339	CONNECTION ADAPT
1	3030342	CONNECT APT-OUT
1	3030344	O-RING
2	3030348	O-RING
1	3030353	HOSE
1	3030356	HOSE
1	3030359	FILTER AS
1	3030361	BRACKET AS
1	3030367	TUBE AS
1	3030369	PIPE
1	3030371	BRACKET AS
3	3030383	CLIP
1	3030384	BRACKET AS
1	3030387	CONNECTOR
1	3030425	CONNECTOR
1	3030446	BOLT
1	3030449	BRACKET
1	3K0360	SEAL-O-RING
1	4B4276	WASHER
2	6I0217	BOLT
3	6I0218	BOLT
1	6I0254	BOLT
2	6I0593	BOLT
2	6I0594	NUT
3	6I0631	BOLT
1	6I0917	BOLT
1	6N4414	COVER-FLTR BASE
4	6V5048	SEAL-O-RING
1	7R4255	WASHER
4	9S8002	PLUG-O-RING

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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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%
0-2000 hrs	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 9.5-hour job
NOTE: The breakdown for the 9.5 hour job is as follows. 1.5 hours will be allowed for a diagnostic leak off check. NOTE: If the results of the leak off check are <50 ml/30 sec 3 hours will be allowed for filter change. NOTE: If the results of the leak off check are >50 ml/30 sec 4 additional hours will be allowed for a complete fuel system change.<

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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Prior to any work being carried out the fist step is to calculate the average leak off rate following the below diagnostic test

To calculate the leak off rate it is required that 3 of the following test are made, from the 3 tests an average should be establish to determine the leak off rate.

If the leak off rate is below 50 ml/30sec then ONLY the improved filtration system needs to be applied.

If the leak off rate is above 50 ml/30sec then along with the filtration kit you will also need to change the high pressure system

Diagnostic Test

High leak off of the electronic unit injector on certain rock drill applications.

Introduction: There have been occurrences of excessive fuel leakage past the electronic injectors on C6.6 engines installed in some rock drills.

Problem: Accelerated wear on the delivery valve results in an increased fuel leak rate. The high pressure pump can not generate enough fuel flow or volume to compensate for the leak off rates above a critical value of 50ml per 30 seconds of cranking at a speed of 150 rpm.

Solution: The fitting of an additional fuel filter assembly ? following an assessment of the condition of the fuel leak off system.

Electronic unit injector leak off test.

Ensure that the engine is shut down. Locate the fuel leak off connector (1) on the cylinder head.

Image1.1.1

Remove the leak off pipe (2) from the connection on the cylinder head (1). Use a clean rubber hose, two hose clips and a suitable bolt to make a sealed cap (3) for the end of the fuel leak off pipe (2). Insert a bolt (4) into the end of the rubber hose (6). Secure the bolt to the rubber hose with a hose clip (5). Place the rubber hose assembly (3) onto the end of the fuel leak off pipe (2) and tighten the hose clip (7).

Image1.2.1

Push a clean length of plastic hose (8) onto the leak off connector (1) on the cylinder head. Place the opposite end of the plastic hose (8) into a clean, graduated fuel container (9).

Image1.3.1

Disconnect the three wiring harness connectors (10) on the top cover in order to prevent the engine from starting.

Image1.4.1

Crank the engine with the starter motor for 30 seconds.

Record the amount of fuel that has been collected in the container from the leak off connector on the cylinder head.

NB: Repeat test 3 times to calculate average

If more than 50ml of fuel has been collected from the 30 second crank then the injectors have high injector leak off. If high injector leak off is diagnosed replace all injectors ? refer to Electronic unit injector removal procedure (all injectors).

If less than 50ml of fuel has been collected during the 30 second crank test, then the injectors do not have high leak off and the leak off pipe (1) should be reconnected to the cylinder head and the three wiring harness plugs (10) should be reconnected.

Rework for improved fuel filter arrangement

Please read this bulletin in full before engaging in rework activity.

Ensure all fuel system components (and the surrounding area) are cleaned externally and free from debris, prior to removing fuel system components ? see section ?Engine Clean? in the OMM. Isolate fuel supply at the valve on the tank and isolate power at the isolator to ensure the engine can not be cranked.

Remove the fuel pipe shown in figure 1.6.1, which fits between the fuel filter and ECM fuel outlet connector along with the two pipe clips. Ensure that all connections are capped ? use anti contamination kit 278-4138.

Image1.6.1

Remove the fuel pipe shown in figure 1.7.1, which fits between the fuel filter and the high pressure pump (this can be discarded) ensuring the high pressure pump connection is capped.

Disconnect the air bleed pipe connection from the top of the fuel filter. Remove the fuel filter assembly and its mounting plate (components shown Fig 1.7.2).

Image1.7.1

Image1.7.2

Disconnect and remove the low pressure fuel line assemblies as shown in figure 1.8.1 discard the fuel line and cap the open connections.

Remove the pipe support bracket shown in figure 1.8.2 and discard

Fit bracket 303-0361 to the induction cover using three fixings (part 6I-0218) and torque them to 28Nm +/- 7Nm as per figure 1.8.3

Fit bracket (303-0371) to the timing case using two 124-3815 fixings and torque to 28Nm +/- 7Nm as per figure 1.8.4

Image1.8.1

Image1.8.2

Image1.8.3

Image1.8.4

Fit bracket 303-0384 to the cylinder head using two 100-4830 fixings and torque to 55Nm +/- 10Nm as shown in figure 1.9.1

Fit bracket 303-0449 to the cylinder head front face using two 100-4830 fixings and torque to 55Nm +/- 10Nm as per figure 1.9.2

Image1.9.1

Image1.9.2

Fit pipe 303-0369 to the common rail relief valve (1) as shown in figure 1.10.1 - the fuel pump leak off quick connector (2) and the upper pipe support clip (3). At the relief valve replace the seal part number 224-8978 in the compression fitting. Push the pipe fully into the fitting and tighten the nut by hand. Ensure the body of the fitting does not move and tighten the nut 1 and ? turns.

Image1.10.1

Fit fuel filter assembly 303-0359 to bracket 303-0361 on the induction cover using two 6I-0594 fixings and torque to 55Nm +/- 10Nm as per figure 1.11.1

Image1.11.1

Fit the steel pipe assembly 303-0367 to the fuel pump inlet spigot and final filter outlet spigot as shown in figure 1.12.1 Push both ends fully home. Tighten the nuts by hand. Ensure the body of the fitting does not move and tighten the nuts 1? turns. Access to the lower fitting is restricted and a crows foot type offset wrench may be required.

Image1.12.1

Fit intermediate filter assembly (303-0372) to bracket part number 303-0449 (on the front face of the engine) using two 6I-0217 fixings and torque to 28Nm +/- 7Nm as per figure 1.13.1

Image1.13.1

Image1.13.2

Fit hose 303-0353 (as shown in figure 1.14.1) between the intermediate fuel filter fitted to the front face of the engine and the final fuel filter (mounted on the side of the engine) ? torque the hose swivel nuts to 34Nm +/- 3Nm.

Image1.14.1

Fit hose 303-0356 (as shown in figure 1.15.1) between the intermediate fuel filter assembly and the ECM fuel outlet connections ? torquing the hose swivel nuts to 34Nm +/- 3Nm. Fit the ECM compression outlet elbow onto the outlet spigot and push fully into the fitting. Tighten the nut by hand, orientate the fitting horizontally and tighten the nut 1 1/4 turns ? ensuring the components are supported.

Image1.15.1

Image1.15.2

Fit the three hose securing clips (303-0383) using 6I-0631 fixings and torque to 12Nm +/- 3Nm. Two clips fit to the bracket on the front face of the engine and the third fits the bracket secured to the timing case as shown in figure 1.15.2

The pipe work on the remote fuel filter needs to be modified ? disconnect the fuel hose from the elbow connector as shown in figure 1.16.1 and retain the 7/8? JK connector to be reused later on

Image1.16.1

Image1.16.2

A 90? ?? elbow (Fig 1.17.5) needs to fitted to the new remote primary fuel filter assembly as shown in figure 1.16.2 The fuel hose that was disconnected will fit directly to the stop tap, which needs to be refitted in a vertical orientation.

Image1.17.1

Image1.17.2

Image1.17.3

Image1.17.4

The 90? 7/8? elbow taken from the fuel line now needs to be fitted directly to the hydraulic pump as shown ? item ?A?. The hydraulic pump is timing case mounted directly below the high pressure pump. A 45? 7/8? fitting was originally fitted directly to the hydraulic pump where the 90? elbow has been fitted. A new 45? 7/8? connector needs to be fitted between the tee piece and the hose ? item ?B?.(Fig 1.17.1)

Figure 1.18.1 shows the final on engine filter and fuel line arrangement