PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN MACHINES AND INDUSTRIAL APPLICATIONS POWERED BY C6.6 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN MACHINES AND INDUSTRIAL APPLICATIONS POWERED BY C6.6 ENGINES

Usage:

REBE1515-00

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23Feb2007

U-71

A-58

D-58

O-65

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN MACHINES AND INDUSTRIAL APPLICATIONS POWERED BY C6.6 ENGINES
1252		PI31227

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31227" 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 "PI31227" 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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COMPLETION DATE	TERMINATION DATE
31Aug2007	29Feb2008

PROBLEM

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The high-pressure fuel line (290-3910) fitted between the fuel pump and the fuel manifold can see high vibration under certain conditions. This vibration could possibly result in fuel line failure.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
120M	B9N00130-00144
12M	B9R00012-00021
938H	LKM00135-00142 MJC00038-00058
953D	LBP00155-00165
963D	LCS00210-00221
AP-655D	GNZ00200-00203
CP-563F	C5P00101-00102
CP-573F	C6P00100
CS-563F	C5S00101-00102
CS-573F	C6S00100
CS-583F	C8S00101
D5P LGP	DHA00207-00214
D5P XL	FBH00329-00339
D6N XL DS	JAH00154-00155
IT38H	MCJ00183-00184
R1300GII	RSL01501-01530

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

C6.6 Tier 3

66600211-00212, 215, 233-247, 255-263, 265-268, 277-307, 309-350, 354-363, 372-374, 377-378, 382-390, 392-404, 406-410, 412-413, 415-429, 431-483, 486-519, 528-532, 543-545, 547-554, 556-564, 566-593, 596-601, 603-618, 620-649, 659, 664-674, 676-677, 679-695, 697-710, 712-722, 724-754, 756, 760-761, 764, 767-777, 779-819, 822-824, 826-831, 833-834, 836-841, 843-862, 864, 866-868, 870-918, 922-926, 928-944, 962-966, 968-987, 989-991, 993-997, 999-1004, 1021-1046, 1061-1068, 1076-1089, 1109-1117, 1119-1133, 1135, 1137-1151, 1153-1155, 1173-1177, 1179-1180, 1182-1195, 1197-1199, 1219, 1224-1225, 1260-1263, 1266-1275, 1282-1288, 1290-1295, 1297-1304, 1315-1328, 1332-1341, 1343-1348, 1352-1355, 1361, 1396, 1401-1403, 1419-1429, 1432-1433, 1436, 1438-1439, 1441, 1453, 1467, 1493-1499, 1501-1507, 1509, 1513-1521, 1535, 1537-1538, 1540, 1544, 1547, 1550-1551, 1554-1556, 1560-1561, 1590, 1592

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2388028	CABLE-TIES
4	2414291	SCREW
1	2784138	PROTECTION KIT
4	2801889	CLAMP
4	2801890	CLAMP
4	2801891	ISOLATOR
1	2903910	TUBE FUEL-INJ
1	3002940	BRACKET
4	6I0254	BOLT
2	6I4374	BOLT
*****Group 2*****
1	2388028	CABLE-TIES
4	2414291	SCREW
1	2784138	PROTECTION KIT
4	2801889	CLAMP
4	2801890	CLAMP
4	2801891	ISOLATOR
1	2903910	TUBE FUEL-INJ
1	3002940	BRACKET
4	6I0254	BOLT
2	6I4374	BOLT

ACTION REQUIRED

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Install bracket (300-2940) to provide support to the fuel pipe and overcomes the root cause vibration.

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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 2.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 2

PARTS DISPOSITION

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 ADDITIONAL SUPPORT FOR THE FUEL DELIVERY LINE

MODELS INVOLVED - C6.6, 120M, 12M, 938H, 953C, CP-563F, CP-573F, CS-563F, CS-573F, CS-583F, D5N LGP, D5N XL and RI1300GII

Dear Caterpillar Product Owner:
New high-pressure fuel line (290-3910) fitted between the fuel pump and the fuel manifold can see high vibration under certain conditions. This vibration could possibly result in fuel line failure. 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 23Feb2007 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 23Feb2007 Service Letter

Rework Procedure

This is a two-stage rework procedure. Stage 1 replaces the fuel pipe between the fuel pump and fuel manifold. Stage 2 adds a bracket and clamp for the fuel pipe.

Stage 1 of rework
Assembly instructions for fitting new fuel pipe (pump to fuel manifold) (Items 1 through to 13)

1.Thoroughly clean the area around the pipe to be removed (290-
3910)

2.Remove existing pipe and pipe clamps

3.Fit new clean caps (Protection Kit 278-4138) to the exposed
fuel pump and fuel manifold connections if the new pipe is not
going to be assembled immediately.

4.Check that the HP pipe is free from faults and both ends of
the pipe have the protective caps fitted. Do not remove the
caps until the point at which the pipe is fitted.

5. Fit three rubber isolators (280-1891) onto the pipe.

6.Assemble clamps around rubber isolators (280-1890 back,
nearest cylinder head 280-1889 front) onto the pipe with M5
cap screws (241-4291) finger tight.

7.Remove protective caps from the pipe ends, fuel pump outlet
and fuel manifold inlet. Fit the pipe, loosely tightening the
nuts at both ends, and ensuring the pipe ends are fully
engaged in the conical seats.

8.Fit M8 bolts (6I0254), loosely tightening them through the
clamps and into the cylinder head.

9.Tighten the nuts at both ends of the pipe to a torque of 30Nm
? 2.4Nm.(22 ? 1.5 lbf ft)

10.Ensure torque is applied perpendicular to the thread.
11.Tighten the M8 bolts into the cylinder head to a torque of
22Nm ? 5.5Nm. (16 ? 4 lbf ft)

12.Tighten the M5 cap screw to a torque of 10Nm ? 1.0Nm.( 7 ? 0.7 lbf ft)

13.Pipe must not touch any other component over its length
except where clipped (see fig 1.1.1).

Image1.1.1

Stage 2 of rework
Assembly instructions for addition of HP pipe clamp and bracket
(Items 14 through to 23)

14.Remove front 2 fuel manifold bolts (6I4793)and washer.
Discard.

15.Assemble bracket (300-2940) to manifold

16.Fit two new M8 x 60LG bolts 6I4374 to hold bracket in
position. Do not tighten.

17.Assemble heavy duty clamp rubber and clamps (part numbers
280-1891, 280-1890, 280-1889, 241-4291)to HP pipe as
instructions 5 and 6 above. See figure 2 for orientation.

18.Slide clamp into place, aligning slotted hole with threaded
hole in bracket. Finger tighten M5 cap screw holding clamp in
place.

19.Assemble M8 x 30LG (6I0254) bolt holding clamp to bracket.
The position of the bracket on the manifold may have to be
adjusted to make this easier. Align the clamp with the
bracket.
N.B. Do not apply excessive pressure to the pipe.

20.Tighten M8 x 60LG bolts down to manifold to a torque of 22Nm
?5.5Nm. (16 ? 4 lbf ft)

21.Tighten M8 x 30LG bolt fastening clamp to bracket to a torque
of 22Nm ?5.5Nm. (16 ? 4 lbf ft)

22.Torque M5 cap screw to 10Nm ? 1.0Nm. ( 7 ? 0.7 lbf ft)

23.Finally cable tie the wiring loom tightly to the bracket to
prevent chafing, see figure 2 for position and orientation.