PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER BASE MOUNTING BRACKET ON CERTAIN RIGHT HAND SERVICE C32 ACERT MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER BASE MOUNTING BRACKET ON CERTAIN RIGHT HAND SERVICE C32 ACERT MARINE ENGINES

Usage:

REBE6207-01

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10Aug2010

(Revised 24Sep2010)

U-312

A-241

D-267

O-270

TM-16

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER BASE MOUNTING BRACKET ON CERTAIN RIGHT HAND SERVICE C32 ACERT MARINE ENGINES
1274 1705 1261		PI10813

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10813" 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 "PI10813" 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:	This Revised Service Letter replaces the 10Aug2010 Service Letter. Changes have been made to Action Required and Service Claims Allowance annotation.

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PROBLEM

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The 338-1501 Mounting Bracket (right hand service) can allow excessive movement of the fuel filter and fuel filter base which can lead to a failure of the hollow fuel filter mounting stud on certain C32 Acert Marine Engines. If the stud fails it may allow the fuel filter to come loose and or fall off dumping fuel into the engine compartment. This failure in conjunction with other factors or circumstances, may result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C32	RNC02189-02190, 2253, 2256, 2299, 2392-2393, 2443, 2452, 2484, 2563, 2574, 2600, 2613, 2651, 2664, 2671, 2676, 2679, 2706-2707, 2715, 2719, 2729, 2735, 2738, 2745, 2771, 2782, 2793, 2800, 2813, 2815, 2817, 2848, 2857, 2874, 2878, 2882-2883, 2921, 2930, 2951, 2962, 2971, 2981-2982, 2992, 3008, 3015, 3022, 3024, 3038, 3045, 3048-3049, 3054, 3069, 3081-3082, 3086, 3101, 3104, 3108, 3116-3117, 3135, 3145, 3147-3148, 3157, 3161, 3167, 3181, 3185-3186, 3189 T3T00107, 109-110, 114, 117-118, 121, 123, 128, 130, 135, 140, 149, 155, 160, 163, 166-167, 179, 191, 198-200, 204, 211, 213, 215, 217, 223, 226-227, 229, 231, 234, 236, 239, 241, 243-245, 247, 250-251, 256, 258, 260-261, 268, 274-275, 279, 282-283, 287, 289, 291, 295-296, 298-299, 305, 307, 309-310, 313-314, 317, 323-324, 328, 332, 334, 336-338, 341-342, 344, 349, 364, 367-368, 370-377, 380, 383

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

C32

RNC02186, 2218, 2233, 2241, 2250, 2263, 2291, 2307, 2318, 2330-2331, 2334, 2355, 2359, 2363, 2378, 2383, 2396, 2408, 2426, 2431, 2460, 2470, 2500, 2505, 2512, 2516, 2532, 2534, 2546, 2552, 2555, 2571-2572, 2586, 2594, 2603, 2607, 2610, 2614, 2617, 2641, 2645, 2648, 2652-2655, 2665-2668, 2675, 2680, 2686-2687, 2704, 2716, 2737, 2746, 2748-2750, 2752, 2762-2763, 2783, 2788, 2803, 2819, 2822, 2825, 2827, 2833, 2840, 2842-2843, 2845, 2851, 2853-2854, 2858-2860, 2866, 2870, 2872, 2890, 2893-2894, 2899, 2903, 2906, 2913, 2925, 2927, 2935, 2957, 2959, 2966, 2970, 2973, 2990, 2994-2995, 2998, 3001-3002, 3012, 3018, 3025, 3027-3029, 3032, 3036, 3039, 3042, 3050, 3053, 3057, 3059, 3064, 3068, 3071, 3073, 3077, 3084, 3087, 3090, 3095, 3098-3099, 3113, 3118-3119, 3124, 3130, 3134, 3142, 3144, 3146, 3151, 3158, 3172-3173, 3178, 3182, 3187, 3196, 3198

T3T00137-00138, 142, 145, 151-152, 154, 159, 162, 164, 172, 176-177, 182-184, 193-194, 210, 212, 216, 237, 262, 265, 269, 272, 286, 292, 316, 325, 357, 360, 363, 365-366

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	6V8398	SEAL-O-RING-ORFS
1	1402576	PAINT-WHITE
1	3543496	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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	1P0436	GASKET-PRM PUMP
1	1R0755	FILTER AS-FUEL
3	3K0360	SEAL-O-RING
1	6N1127	SHIELD-OIL FIL
1	6V3922	SEAL-O RING
1	6V4589	SEAL-O-RING
6	6V8397	SEAL-O-RING-ORFS
4	6V8398	SEAL-O-RING-ORFS
2	7F9090	SCREW-DRIVE
1	7J9108	SEAL-O-RING-ORFS
3	8L2786	SEAL-O-RING
1	1402576	PAINT-WHITE
3	2147568	SEAL-O-RING-STOR
1	2379313	BASE AS. -F FILT
1	3543496	BRACKET AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% 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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Action required for group 1:
For engines that are listed in group 1 (not installed) only the 338-1501 Mounting Bracket will need to be replaced with the new 354-3496 Mounting Bracket. Refer to the attached Rework Procedure.

NOTE: If an engine listed in Group 1 has been previously installed. Perform the rework according to Rework Procedure for Group 2 using Parts Needed list for Group 2. Submit claim according to Group 2 Service Claims Allowance Table.

Action required for group 2:
For engines listed in group 2 (delivered in service) the 338-1501 Mounting Bracket will need to be replaced with the new 354-3496 Mounting Bracket as well as the 237-9313 Fuel Filter Base Assembly. Refer to the attached Rework Procedure.

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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%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job for Group 1
No travel is allowed as these engines have not been delivered/installed. NOTE: If an engine listed in Group 1 has been previously installed. Perform the rework according to Rework Procedure for Group 2 using Parts Needed list for Group 2. Submit claim according to Group 2 Service Claims Allowance Table.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-hour job for Group 2
Additional labor may be considered for clean up of fuel and detailing of engine room if performed after failure. NOTE: If an engine listed in Group 1 has been previously installed. Perform the rework according to Rework Procedure for Group 2 using Parts Needed list for Group 2. Submit claim according to Group 2 Service Claims Allowance Table. Provide details in claims story that engine has been previously installed.

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PARTS DISPOSITION

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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

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER BASE MOUNTING BRACKET ON CERTAIN RIGHT HAND SERVICE C32 ACERT MARINE ENGINES

MODELS INVOLVED - Marine C32 ACERT

Dear Caterpillar Product Owner:

The mounting bracket and fuel filter base needs to be replaced on the products listed below. The 338-1501 Mounting Bracket (right hand service only) can allow excessive movement of the fuel filter and fuel filter base which can lead to a failure of the hollow fuel filter mounting stud. If the stud fails, it may allow the fuel filter to come loose and / or fall off, causing fuel to be dumped into the engine compartment. This failure in conjunction with other factors or circumstances, may result in a risk of personal injury or death. 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 10Aug2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 10Aug2010 Service Letter

Rework Procedure

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Group Number 1

Group 1 (non delivered / not in service):
Note: Be prepared to catch fuel in a suitable container during disassembly. Properly dispose of the fuel when rework procedure is completed.

1) Remove the hose assembly from the 6V-8981 Adapter Elbow. Then remove the 6V-8981 Adapter Elbow from the 338-1501 Mounting Bracket. (See Image 1.1.1)

NOTE: This procedure will not require any additional fuel lines to be removed.

2) Keep the 1R-0755 Fuel Filter and 237-9313 Base Assembly in one piece.
- While properly supporting the fuel filter and filter base assembly, remove the 2 mounting bolts that secure the 237-9313 Fuel Filter Base to the 338-1501 Mounting Bracket. (See Image 1.1.1)

3) Remove the 4 mounting bolts that secure the 338-1501 Mounting Bracket to the engine.

4) Install the new 354-3496 Mounting Bracket on the engine securing with the 4 mounting bolts and tighten to a torque of 47 +/- 9 Nm. (See Image 1.1.1)

5) Reinstall the 237-9313 Fuel Filter Base with filter onto the new 354-3496 Mounting Bracket and tighten the 2 mounting bolts to a torque of 47 +/- 9 Nm. (See Image 1.1.1)

6) Reinstall the 6V-8981 Adapter Elbow into the 354-3496 Mounting Bracket and secure with 6V-9169 Nut Assembly. Tighten to a torque of 65 +7/-0 (Nm).

7) Reinstall the hose assembly to 6V-8981 Adapter Elbow and properly tighten as outlined in SENR3130.

8) Paint the new 354-3496 Mounting Bracket and touch up all painted surfaces that may have been damaged during this procedure.

9) When the engine gets put into service, check for fuel leaks in this area (repair as necessary).

Image1.1.1

Group Number 2

Group 2 (delivered / in service):

Note: Be prepared to catch fuel in a suitable container during disassembly. Properly dispose of the fuel when rework procedure is completed.

1) Remove the 1R-0755 Fuel Filter from the engine and allow to drain in suitable container.
- Properly dispose of the filter.

2) Mark all fuel lines and sensor locations before removing from the 237-9313 Fuel Filter Base, this will assure they are properly located during reassembly to the new 237-9313 Fuel Filter Base.

3) Remove all fuel lines from the 237-9313 Fuel Filter Base including the fuel supply line from the vessel that is connected to the 6V-8981 Adapter Elbow. (See Image 2.1.1)

4) Remove all fittings, sensors and priming pump from the old 237-9313 Fuel Filter Base.

5) Remove the 6V-8981 Adapter Elbow from the 338-1501 Mounting Bracket. (See Image 2.1.1)

6) While properly supporting the 237-9313 Fuel Filter Base Assembly, remove the 2 mounting bolts that secure the 237-9313 Fuel Filter Base to the 338-1501 Mounting Bracket. (See Image 2.1.1)

7) Remove the 4 mounting bolts that secure the 338-1501 Mounting Bracket to the engine.

8) Install the new 354-3496 Mounting Bracket on the engine securing with the 4 mounting bolts and properly tighten to a torque of 47 +/- 9 Nm. (See Image 2.1.1)

9) Install the 6N-1127 Shield onto the new 237-9313 Fuel Filter Base before installing the 237-9313 Fuel Filter Base on the engine. (See Image 2.1.2)
- Using a flat punch and hammer, drive the two 7F-9090 Drive Screws into the 237-9313 Fuel Filter Base securing the shield. (See Image 2.1.2)
- Make sure that the screws are completely bottomed out to keep from interfering with the top of the fuel filter when installed. (See Image 2.1.2)

10) Install the new 237-9313 Fuel Filter Base and shield onto the new 354-3496 Mounting Bracket.
- Properly tighten the 2 mounting bolts to a torque of 47 +/- 9 Nm. (See Image 2.1.1)

11) Install new o-ring seals on all fittings and sensors.

12) Install the 194-6725 Fuel Pressure Sensor, 246-4297 Fuel Temperature Sensor, and 281-2725 Valve Group into the new 237-9313 Fuel Filter Base.
Attention: A special torque specification is required for these components, refer to Image 2.1.3 for the proper torque values.

13) Install all fittings into proper location on the new 237-9313 Fuel Filter Base. Reference SENR3130 for proper torque specifications for all of the fittings.

14) Install all hose assemblies in the proper location. Reference SENR3130 for proper torque specifications for the hose assembly fittings.

15) Install the fuel-hand priming pump with a new gasket. Reference SENR3130 for the proper torque specifications for the mounting bolts.

16) Install a new 1R-0755 Fuel Filter and properly tighten as outlined on the filter housing.

17) Paint the new 237-9313 Fuel Filter Base, new 354-3496 Mounting Bracket and new 1R-0755 Fuel Filter.
- Touch up all painted surfaces that may have been damaged during this procedure.

18) Prime the fuel system while checking for fuel leaks before starting the engine.
- Start the engine and re-check for leaks (repair as necessary).