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

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

Usage:

REBE1377-00

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24Oct2006

U-689

D-650

O-672

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR FITTING A MODIFIED FUEL FILTER ARRANGEMENT TO CERTAIN C6.6 ENGINES USED IN TAMROCK ROCKDRILL APPLICATIONS
1262 1258 1261 1263		PS42273

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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 "PS42273" 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	66600431, 497-506, 544-545, 547-549, 719-722, 742-748, 788-796, 805-806, 923-926, 928-937, 1045-1046, 1061-1068, 1076-1089, 1173-1177, 1224-1225, 1260-1263, 1301-1304, 1332, 1374-1376

PARTS NEEDED

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Qty	Part Number	Description
1	1013895	BOLT
1	1127704	BOLT
1	1415138	BASE AS-F FILTER
1	1P0436	GASKET-PR PUMP
1	1R0751	FILTER AS-FUEL
1	3030360	FILTER AS
1	3030361	BRACKET AS
1	3030367	TUBE AS
1	3030370	HOSE
1	3030387	CONNECTION
1	3030392	CONNECT INLET
3	6I0218	BOLT
2	6I0594	NUT
1	6N4414	COVER-FLTR BASE
1	6V5048	SEAL-O-RING
1	9S4182	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. NOTE: One hour will be allowed to fabricate a bracket.

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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

Ensure all fuel system components and the surrounding area are clean and free from debris ? prior to removing fuel system components. See the ?Engine ?Clean? section of the Operation and Maintenance Manual. Isolate the fuel feed at the tank and isolate power to ensure the engine can not be started. Additionally use anti contamination kit 278-4138 to cap fuel system components.

Remove the existing secondary fuel filter assembly from the chassis of the vehicle (Fig 1.6.1) and replace it with intermediate secondary filter assembly part No. 303-1453 (Fig 1.7.1 see assembly instructions Fig 1.7.2) The position of the mounting holes for the intermediate filter will be different and the bracket shown below (Fig 5) will need to be fabricated.

Image1.6.1

Connect the free end of hose running from the ECM to the extended 90? elbow on the intermediate filter assembly as shown in Fig 1.6.1 left hand side of filter

Image1.7.1

Image1.7.2

Image1.7.3

Fit bracket 303-0361 to the induction cover using three 6I-0218 fixings and tighten them to a torque of 28 Nm +/- 7 Nm. See Fig 1.8.1

Image1.8.1

Remove the existing high pressure fuel pump inlet hose and assemble steel pipe 303-0367 onto the open spigot and engage fully (Fig 1.9.1). The compression fitting at the high pressure inlet end of the steel pipe should then be tightened just enough so that the pipe can be orientated without rotating if left unsupported. The output spigot of the final filter assembly 303-0360 should then be inserted into the free end of steel pipe 303-0367. The whole assembly should then be rotated onto the mounting studs on bracket 303-0361. (see Fig 1.10.1)

Image1.9.1

Secure the filter head using two 6I-0594 nuts and torque to 55Nm +/- 10Nm.

Tighten both compression fittings until they grip the tube firmly enough to prevent movement. Then tighten a further 1 to 1? turns to seal the pipe to the spigots. Access to the lower fitting is restricted and a crows foot type tool may be required to gain access.

Where a compression fitting has already been assembled to a spigot ? tighten the nut until a sharp rise in torque is felt, then tighten a further 1/6 to 1/3 of a turn to seal.

Take the second 303-0370 hose and connect one end to the shorter 90? elbow on the intermediate filter (see ?A? on Fig 1.10.1) and tighten to 27Nm +/- 3.0Nm. The other end of the hose connects to the extended 90? elbow on the final filter (see ?B? on Fig 1.10.1) ? torque as above.

Image1.10.1

Connect the existing air bleed hose to the top of the final filter (Fig 1.11.1) assembly using the existing banjo bolt fitted with new sealing washers. Fig 1.11.2 shows final assembly of the air bleed hose.

Image1.11.1

Image1.11.2

Manually prime the fuel system using the instructions in ?fuel system ? prime? in the OMM section of the literature for the C6.6 and run the engine to normal operating temperature to check for leaks.