PRODUCT SUPPORT PROGRAM FOR TESTING COOLANT SAMPLE FOR PRESENCE OF DIESEL FUEL AND IF NECESSARY REPLACE THE CYLINDER HEAD FOR CERTAIN C27 AND C32 ENGINES. Caterpillar


PRODUCT SUPPORT PROGRAM FOR TESTING COOLANT SAMPLE FOR PRESENCE OF DIESEL FUEL AND IF NECESSARY REPLACE THE CYLINDER HEAD FOR CERTAIN C27 AND C32 ENGINES.

Usage:

REBE1774-00

03Apr2007


U-125
A-107
D-105
O-113
TM-5

 
Before/After
  
  

PRODUCT SUPPORT PROGRAM FOR TESTING COOLANT SAMPLE FOR PRESENCE OF DIESEL FUEL AND IF NECESSARY REPLACE THE CYLINDER HEAD FOR CERTAIN C27 AND C32 ENGINES.

1350
PS42375
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 "PS42375" 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.

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.


TERMINATION DATE

30Apr2009

PROBLEM

The existing cylinder head could be porous on certain C27 and C32 engines. If the cylinder head is porous, it can allow diesel fuel to enter into the cooling system, which can damage the radiator seals.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
777F  JRP00281-00476, 533
*******Group  2*******
C27 DWB00102-00239, 241-256

TWM00114-00183, 185-199, 202-227, 229-267
C32 SMP00169-00176, 178-188

SXC00400-00436, 438-441, 443-469, 472, 482-591, 593, 595-621, 627-658, 660-661, 665-676, 678-798, 800-839, 841-863, 865-871, 873-874, 876-888, 890-913, 915, 917, 922-924, 926-929, 932-933, 936-938, 945, 947-953, 956-959, 963, 965-967, 970-971, 973-977, 979, 983-984, 986-990, 993-996, 1005

TLD00104-00146
*******Group  3*******
C32  RNC02335, 2367-2368, 2375-2376, 2381-2384, 2386-2387, 2389-2456, 2458-2606, 2608-2619, 2621-2635, 2637-2642, 2645-2646, 2648-2652, 2656-2659, 2663-2671, 2696-2698, 2704, 2706-2707, 2709
*******Group  4*******
D10T  RJG00725-01026
*******Group  5*******
773F  EED00278-00346
775F  DLS00280-00339
*******Group  6*******
844H  BTW00158-00164
990H  BWX00298-00340

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
1 6V5553 SEAL-O-RING
6 9X7317 SEAL-FUEL SYSTEM
2 0307937 CONNECTOR-PORT
2 1075769 SEAL-O-RING
6 1299452 GASKET-EXH MANF
2 2147568 SEAL-O-RING-STOR
1 2226456 SEAL
3 2247506 SEAL-ISOLATION
1 2253099 GASKET-CYL HEAD
1 2265613 GASKET
6 2303728 SEAL-FUEL SYSTEM
6 2303775 SEAL-FUEL SYSTEM
1 2391139 SEAL
2 2415766 HOSE
2 2485513 REGULATOR-TEMP
1 2525706 HOSE
4 2725437 SEAL
10 2725438 SEAL
1 2848892 HEAD GP-CYL BSC
*******Group 2*******
1 6V5553 SEAL-O-RING
6 9X7317 SEAL-FUEL SYSTEM
2 0307937 CONNECTOR-PORT
2 1075769 SEAL-O-RING
6 1299452 GASKET-EXH MANF
2 2147568 SEAL-O-RING-STOR
1 2226456 SEAL
3 2247506 SEAL-ISOLATION
1 2253099 GASKET-CYL HEAD
1 2265613 GASKET
6 2303728 SEAL-FUEL SYSTEM
6 2303775 SEAL-FUEL SYSTEM
1 2391139 SEAL
2 2485513 REGULATOR-TEMP
1 2848892 HEAD GP-CYL BSC
*******Group 3*******
1 2H3935 SEAL-O RING
1 6V5553 SEAL-O-RING
6 9X7317 SEAL-FUEL SYSTEM
2 0307937 CONNECTOR-PORT
6 1299452 GASKET-EXH MANF
2 2147568 SEAL-O-RING-STOR
1 2226456 SEAL
3 2247506 SEAL-ISOLATION
1 2253099 GASKET-CYL HEAD
1 2265613 GASKET
6 2303728 SEAL-FUEL SYSTEM
4 2303775 SEAL-FUEL SYSTEM
1 2391139 SEAL
2 2485513 REGULATOR-TEMP
1 2848892 HEAD GP-CYL BSC
*******Group 4*******
12 6I2431 SEAL
1 6V5063 SEAL-O-RING
1 6V5553 SEAL-O-RING
6 9X7317 SEAL-FUEL SYSTEM
2 0307937 CONNECTOR-PORT
9 1064572 HOSE
2 1075769 SEAL-O-RING
6 1299452 GASKET-EXH MANF
2 2147568 SEAL-O-RING-STOR
1 2226456 SEAL
3 2247506 SEAL-ISOLATION
1 2253099 GASKET-CYL HEAD
1 2265613 GASKET
6 2303728 SEAL-FUEL SYSTEM
6 2303775 SEAL-FUEL SYSTEM
1 2391139 SEAL
2 2485513 REGULATOR-TEMP
1 2848892 HEAD GP-CYL BSC
*******Group 5*******
1 6V5553 SEAL-O-RING
6 9X7317 SEAL-FUEL SYSTEM
2 0307937 CONNECTOR-PORT
2 1075769 SEAL-O-RING
6 1299452 GASKET-EXH MANF
2 2147568 SEAL-O-RING-STOR
1 2226456 SEAL
3 2247506 SEAL-ISOLATION
1 2253099 GASKET-CYL HEAD
1 2265613 GASKET
6 2303728 SEAL-FUEL SYSTEM
6 2303775 SEAL-FUEL SYSTEM
1 2391139 SEAL
1 2404851 HOSE
2 2485513 REGULATOR-TEMP
2 2531298 HOSE-HUMP
4 2725437 SEAL
8 2725438 SEAL
1 2848892 HEAD GP-CYL BSC
*******Group 6*******
9 6I2431 SEAL
1 6V5553 SEAL-O-RING
6 9X7317 SEAL-FUEL SYSTEM
2 0307937 CONNECTOR-PORT
2 1075769 SEAL-O-RING
6 1299452 GASKET-EXH MANF
1 1917815 HOSE
2 2147568 SEAL-O-RING-STOR
1 2226456 SEAL
3 2247506 SEAL-ISOLATION
1 2253099 GASKET-CYL HEAD
1 2265613 GASKET
6 2303728 SEAL-FUEL SYSTEM
6 2303775 SEAL-FUEL SYSTEM
1 2391139 SEAL
2 2485513 REGULATOR-TEMP
1 2848892 HEAD GP-CYL BSC
1 2955522 ELBOW

ACTION REQUIRED

1. Remove the radiator filler cap slowly to relieve pressure only when the engine is stopped and the radiator cap is cool enough to touch with your bare hand.
2. After the radiator cap has been removed, smell the air over the radiator filler neck to determine if the odor of diesel fuel is present.
3. If no fuel odor is detected, no further action is required.
4. If fuel odor is detected, obtain and submit and a coolant sample for SOS analysis as defined in the Operation and Maintenance Manual for the machine/engine.
5. If the SOS report shows that there is fuel present in the coolant, proceed to the Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-4000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 1
Note: Resultant damage parts and up to 58 total labor hours for cylinder head replacement, following a positive SOS coolant sample for fuel, will be covered by this Service Letter.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-4000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 2
Note: Resultant damage parts and up to 50 total labor hours for cylinder head replacement, following a positive SOS coolant sample for fuel, will be covered by this Service Letter.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 3*******
0-4000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 3
Note: Resultant damage parts and up to 50 total labor hours for cylinder head replacement, following a positive SOS coolant sample for fuel, will be covered by this Service Letter.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 4*******
0-4000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 4
Note: Resultant damage parts and up to 58 total labor hours for cylinder head replacement, following a positive SOS coolant sample for fuel, will be covered by this Service Letter.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 5*******
0-4000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 5
Note: Resultant damage parts and up to 58 total labor hours for cylinder head replacement, following a positive SOS coolant sample for fuel, will be covered by this Service Letter.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 6*******
0-4000 hrs,
0-36 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 1.0-hour job for Group 6
Note: Resultant damage parts and up to 58 total labor hours for cylinder head replacement, following a positive SOS coolant sample for fuel, will be covered by this Service Letter.



PARTS DISPOSITION

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


Rework Procedure


 
1. Drain coolant from the machine engine cooling system.
2. Disconnect the front and rear fuel lines at the cylinder head.
3. Blow fuel out of the cylinder head fuel rail.

NOTE: Do Not Exceed 80 psi when performing step 3.

4. Install a cap (8S-4950) on one end of the fuel rail on each head. Refer to Illustration 1.1.1
Image1.1.1
 
5. Attach a hose to the other end of the fuel rail and hold the free end of the hose in a cup/bucket of water. Hose shown is a JIC 37o ?6 hose. Refer to Illustration 1.2.1
Image1.2.1
 
6. Pressurize the cooling system with compressed air and regulate pressure between 5-15 psi.

NOTE: Do Not Exceed 15 psi or Cooling System Damage Can Result.

7. Submerse the hose in a cup/bucket of water.
8. Monitor for 10 minutes and check for a steady rate of air bubbles coming out of the hose that is submersed in the cup/bucket of water.
9. If steady stream of air is present, replace the cylinder head, coolant regulators, and both 030-7937 port connectors. Depending on the application, you will need to replace some cooling system seals. (List of seals by application to be included)
10. Once the cylinder heads have been replaced pressure test the head again using the same procedure. Once this has been completed the cooling system should be flushed using instructions listed below.
 
Cleaning the Cooling System
1. Drain all of the coolant form cooling system.
2. Fill the cooling system with clean water.
3. Start engine and run it until the thermostat opens.
4. Add two cups of non-foaming liquid automatic dish washer soap.

Note: Do not use plain dish soap. Aeration of the cooling system and resultant damage could occur.

5. After the soap has bee added run engine for approximately twenty minutes. Check to see if the fuel is breaking up.
6. If the fuel is still not breaking up than add two more cups of soap and run for 10 minutes. Drain mixture from cooling system.
7. Fill cooling system with clean water and check surface for fuel. If fuel is present, repeat steps 3 through 7. When water is clear, drain and rinse the cooling system one more time. Then add coolant and conditioner.
 
 

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