PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL SYSTEM ON CERTAIN C27 AND C32 ELECTRIC POWER GENERATION UNITS OPERATING IN PRIME OR CONTINUOUS ENVIRONMENTS
Usage:
REBE6228-01
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| 07Sep2010 |
| (Revised 27Jun2011) |
U-362
A-286
D-311
O-316
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| Priority | PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL SYSTEM ON CERTAIN C27 AND C32 ELECTRIC POWER GENERATION UNITS OPERATING IN PRIME OR CONTINUOUS ENVIRONMENTS |
|
| 1274 1256 1920 1901 | PI31798 |
|
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| NOTE: | This Program must be administered as soon as possible. When reporting the repair, use "PI31798" 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 "PI31798" 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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| NOTE: | This Revised Service Letter replaces the 07 September 2010 Service Letter. Changes have been made to Affected Product. |
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COMPLETION DATE |
TERMINATION DATE |
| 31Mar2011 | 30Sep2011 |
PROBLEM
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| The existing front fuel supply hoses may not reach full life on engines operating in a prime or continuous environment. |
AFFECTED PRODUCT
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| Model | Identification Number |
| *******Group 1******* | |
| C27 | DWB00102, 105, 109, 111-113, 116-119, 122-126, 129, 131, 133-135, 139-140, 145-146, 149, 151-162, 164, 167-168, 173, 177, 191-193, 195-198, 200-202, 204, 206-216, 218, 220-233, 236-238, 240-248, 250-251, 264, 269-270, 290, 293, 304-320, 322-338, 344, 348-351, 353-354, 363-367, 373-376, 397, 405, 415, 424, 430, 433, 443-446, 449-452, 461-462, 465-468, 476, 479-483, 492-493, 503, 505, 512, 517-518, 521, 527, 532, 535, 538-543, 546, 553, 555, 558, 561, 568, 575-578, 583-585, 590-597, 607-611, 615, 617, 625-626, 629-634, 636-652, 655-657, 660, 666-667, 673-677, 681, 697, 699-700, 705, 712, 720-721, 724, 736, 740, 742-743, 747-754, 757, 761, 765, 767-769, 781, 787, 789, 793-794, 796, 803-804, 806, 810, 813, 819, 831-833, 847-848, 853-864, 876, 891, 896-899, 901-905, 914-916, 918-920, 926, 940-941, 953-954, 962-968, 974, 984-985, 1018 |
| C32 | K7C00103-00106 SXC00300-00304, 307-309, 314, 322, 327, 357, 360, 370-372, 377, 380, 382, 384, 387, 391, 401, 414, 426-428, 430-431, 434-440, 442-443, 446, 448, 466-471, 473-481, 492-493, 496-497, 500-501, 504, 508, 514-515, 522-523, 534, 539, 541-542, 545-552, 556, 558-561, 565, 569, 572, 575-576, 588, 590-591, 593, 612, 615, 621, 627, 632-636, 640-644, 646-648, 660-661, 670, 673-674, 688-689, 715, 717, 724-730, 734, 764, 768-769, 772-774, 776-777, 788-790, 795, 802, 805-806, 813-814, 816, 818-819, 823-824, 827, 836-838, 841-846, 849-853, 855-858, 861-864, 871-872, 875-876, 884-889, 892-894, 896-905, 907, 909-914, 916-921, 925, 929-935, 937-943, 945-955, 957-960, 962-967, 971, 978, 980-983, 985, 988, 992, 999-1000, 1006-1008, 1015-1018, 1020-1022, 1026-1028, 1030-1032, 1034, 1051-1052, 1063, 1073-1083, 1089-1098, 1102, 1113, 1119-1120, 1122, 1124-1125, 1130, 1132-1134, 1137-1139, 1141, 1143-1146, 1148-1153, 1159-1165, 1170, 1172-1176, 1185-1191, 1193-1199, 1201, 1207-1208, 1210, 1212-1216, 1220-1223, 1225, 1227-1228, 1230-1232, 1235, 1237-1239, 1246, 1248-1249, 1251-1254, 1256-1257, 1262-1263, 1267-1270, 1274, 1277-1278, 1281-1285, 1288-1291, 1296-1297, 1300-1302, 1305, 1308-1315, 1317-1324, 1327-1331, 1336, 1348, 1351-1354, 1357, 1359, 1365-1366, 1372-1373, 1375, 1378, 1388-1390, 1396, 1399, 1401-1406, 1408, 1410-1418, 1424, 1426-1429, 1431, 1434, 1436, 1438, 1440-1444, 1446-1448, 1454-1455, 1457, 1459-1460, 1465-1466, 1469-1470, 1479-1481, 1483, 1486, 1494-1500, 1503-1512, 1518-1519, 1521-1538, 1540-1544, 1546, 1549-1581, 1584, 1593, 1613-1617, 1620, 1625-1627, 1630-1631, 1642, 1662, 1667, 1671, 1674-1678, 1681, 1683-1700, 1705-1706, 1714-1716, 1718, 1722, 1725-1770, 1775-1776, 1782-1786, 1788-1801, 1803-1804, 1808-1813, 1815-1818, 1822, 1828-1833, 1839-1841, 1843-1845, 1849-1852, 1854, 1857-1860, 1868-1875, 1877-1894, 1896, 1898-1907, 1909-1911, 1914-1915, 1917-1918, 1920-1923, 1925, 1927-1929, 1934, 1938-1942, 1947-1954, 1957-1965, 1970, 1973-1979, 1983-1984, 1994-1996, 2004-2005, 2007-2008, 2012-2013, 2026-2027, 2034-2035, 2040-2045, 2047-2052, 2054-2058, 2062, 2065, 2071-2074, 2077, 2080-2083, 2087, 2089-2091, 2102, 2104-2105, 2108, 2110-2111, 2115, 2119-2120, 2126, 2129-2144, 2146-2155, 2159-2163, 2165-2180, 2182-2183, 2185-2189, 2191, 2194-2204, 2210-2224, 2228, 2230-2231, 2234-2236, 2240-2242, 2245-2246, 2249, 2252-2255, 2263, 2269, 2272-2288, 2292, 2299-2301, 2303-2306, 2309-2325, 2329-2334, 2346-2353, 2357-2360, 2364, 2366-2369, 2372-2381, 2383-2390, 2395-2398, 2400-2401, 2404-2420, 2422-2427, 2430, 2434-2439, 2450-2453, 2457-2460, 2462-2470, 2473-2476, 2482, 2484, 2487-2488, 2498-2502, 2510-2511, 2515-2520, 2523-2528, 2534-2539, 2541-2547, 2549-2555, 2559, 2561, 2572, 2575-2576, 2582-2584, 2586, 2590-2600, 2604-2605, 2608, 2613-2614, 2619, 2624-2628, 2631-2637, 2643, 2646-2652, 2657-2662, 2666-2667, 2669-2670, 2672, 2676-2678, 2683-2687, 2691, 2698-2727, 2729-2758, 2761-2768, 2772-2773, 2775-2779, 2782-2783, 2790-2801, 2803, 2809-2812, 2814-2819, 2821, 2823-2827, 2829-2836, 2839, 2842, 2846-2854, 2857-2858, 2860-2902, 2904-2907, 2910-2924, 2928-2930, 2945-2946, 2948-2949, 2951-2958, 2965-2966, 2969-2971, 2974-2984, 2986-2987, 2989-2992, 2994, 2996-3000, 3002-3006, 3008, 3010-3011, 3014-3021, 3025-3027, 3036, 3039, 3042-3043, 3055-3057, 3059-3060, 3065-3066, 3074, 3087-3089, 3091-3092, 3095-3099, 3106-3107, 3110-3111, 3115, 3118-3119, 3121-3134, 3138-3144, 3156-3157, 3162-3163, 3165, 3167-3174, 3180, 3182-3184, 3187, 3189-3199, 3204-3205, 3210, 3212, 3214, 3224, 3226-3227, 3229, 3231-3232, 3234, 3236-3242, 3244-3260, 3262-3269, 3271, 3275-3281, 3285-3300, 3302-3303, 3305-3308, 3310-3311, 3315-3321, 3324-3330, 3338-3340, 3342-3346, 3352-3353, 3367-3368, 3374, 3379, 3383, 3391-3394, 3398-3399, 3402-3403, 3405-3410, 3412, 3414-3423, 3427-3435, 3445-3446, 3450-3451, 3454, 3456-3458, 3461-3464, 3466, 3469-3470 |
| PMC32 | MED00100-00115, 117-130, 133-134, 138-141, 143-147, 151-153, 156-157, 160-177 |
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| *******Group 2******* | |
| C27 | DWB01025-01029, 1039, 1044, 1046, 1065, 1080, 1087-1090, 1092, 1094, 1099, 1107-1114, 1116, 1120-1124, 1127-1128, 1136, 1143, 1147-1148, 1153, 1158-1159, 1172-1173, 1175-1176, 1181, 1187-1189, 1209, 1214-1216, 1225, 1228-1230, 1232-1234, 1236, 1238-1242, 1246-1263, 1266, 1279-1280, 1283-1289, 1291-1293, 1308-1309, 1314-1315, 1319, 1321, 1324, 1329, 1331-1335, 1337-1340, 1343-1344, 1346-1347, 1352, 1358-1359, 1365-1366, 1370, 1375, 1384-1387, 1401, 1404, 1409, 1416-1419, 1424, 1428-1429, 1432, 1440, 1442, 1444-1447, 1450, 1454, 1457, 1459, 1463-1464, 1471, 1477, 1484-1486, 1488, 1490-1491, 1495-1500, 1505-1507, 1521-1524, 1528-1529, 1534, 1536, 1538, 1540-1541, 1549, 1551-1556, 1560-1562, 1565-1567, 1570-1572, 1574, 1579-1582, 1584-1586, 1595-1598, 1600, 1607-1608 |
| C32 | K7C00108-00137, 139-205 SXC03471-03472, 3482, 3490, 3494-3496, 3506-3516, 3518-3524, 3528-3530, 3533, 3536-3537, 3539-3541, 3546, 3549-3550, 3553-3555, 3560, 3573-3576, 3578-3582, 3584-3586, 3589, 3591, 3594, 3596-3598, 3603-3604, 3608, 3610, 3618, 3621-3622, 3624, 3627, 3629-3639, 3641-3645, 3647, 3651-3655, 3657-3668, 3670, 3676-3678, 3683-3692, 3698, 3700, 3703, 3705, 3711-3715, 3724-3729, 3732-3734, 3743, 3745-3748, 3750-3751, 3753, 3755, 3757, 3763, 3765-3776, 3778, 3782-3784, 3786, 3788, 3790-3791, 3793-3798, 3804-3805, 3810-3812, 3814-3815, 3817-3820, 3822, 3825, 3827-3831, 3833-3834, 3836-3852, 3854-3858, 3860-3863, 3865-3867, 3872-3873, 3879-3882, 3888-3890, 3896-3900, 3909-3910, 3917-3920, 3928-3931, 3934, 3936-3940, 3943-3944, 3950, 3952-3954, 3958-3969, 3971, 3975-3977, 3983-3986, 3988, 3993-3994, 3997-3999, 4006, 4017-4022, 4027, 4030-4036, 4043-4044, 4047, 4051-4053, 4055-4058, 4060, 4063-4065, 4068-4069, 4071, 4073-4074, 4076-4080, 4082, 4085-4086, 4088-4089, 4093-4094, 4096-4097, 4102-4104, 4110-4114, 4121-4123, 4131-4132, 4135-4143, 4156-4182, 4185-4186, 4188-4205, 4208-4215, 4218-4226, 4228, 4230, 4235, 4240-4241, 4247-4248, 4256, 4259, 4262, 4267-4272, 4279-4280, 4282-4292, 4294-4299, 4303, 4315-4320, 4323-4327, 4329-4330, 4333, 4335-4336, 4339-4344, 4346-4348, 4350-4351, 4353, 4356-4364, 4367-4369, 4371, 4377-4380, 4383-4386, 4388-4403, 4406-4407, 4409-4410, 4414-4416, 4418-4431, 4433-4438, 4440, 4442-4446, 4452, 4454-4467, 4470-4471, 4473, 4475-4478, 4483-4487, 4489-4493, 4495, 4499-4500, 4504-4505, 4510, 4512, 4514, 4516, 4520, 4522-4533, 4535-4540, 4544-4545, 4547-4548, 4556-4559, 4566-4572, 4574, 4577-4580, 4582-4590, 4592-4596, 4598-4631, 4633, 4637-4647, 4649-4652, 4654-4661, 4669-4675, 4677, 4679-4680, 4682-4683, 4686-4687, 4690-4696, 4700-4701, 4703-4706, 4708, 4711-4718, 4722-4729, 4731-4737, 4741-4744, 4750, 4753-4754, 4759-4762, 4767-4769, 4774-4780, 4783, 4785, 4791-4792, 4794, 4799-4802, 4809, 4814, 4817, 4819-4822, 4824-4825, 4830-4833, 4835, 4839-4843, 4846-4859, 4863, 4867-4868, 4871-4872, 4876-4877, 4883-4886, 4890, 4894-4896, 4905, 4907, 4909-4919, 4921-4924, 4926, 4928, 4936-4939, 4946, 4950-4959, 4964-4966, 4971-4978, 4981-4985, 4990-4992, 4997-5001, 5005, 5009, 5012-5013, 5017, 5019, 5021, 5023, 5025, 5028, 5035-5037, 5041, 5044-5046, 5052-5054, 5057-5058, 5067, 5070-5071, 5081-5082, 5086-5087, 5090-5092, 5100, 5106-5108 |
| PMC32 | MED00178-00189, 194 |
PARTS NEEDED
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Qty |
Part Number | Description |
| *******Group 1******* | ||
| 2 | 7V6571 | GROMMET (Before Failure Only) |
| 1 | 8C3089 | SEAL-O-RING (Before Failure Only) |
| 2 | 8T1889 | CLIP-2 PIECE (Before Failure Only) |
| 2 | 8T1890 | CLIP-2 PIECE (Before Failure Only) |
| 2 | 1473396 | CONNECTOR-PORT (Before Failure Only) |
| 2 | 2147568 | SEAL-O-RING-STOR (Before Failure Only) |
| 2 | 3227616 | HOSE AS. (Before Failure Only) |
| 1 | 3274448 | VALVE GP-CHECK-A (Before Failure Only) |
| 1 | 3394983 | KIT-SPRING (Before Failure Only) |
| 1 | 3459194 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459195 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459213 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459215 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459216 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459218 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459219 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459220 | SOFTWARE GP-ELEK (Before Failure Only) |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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 | 8C3089 | SEAL-O-RING (Before Failure Only) |
| 2 | 3227616 | HOSE AS. (Before Failure Only) |
| 1 | 3274448 | VALVE GP-CHECK-A (Before Failure Only) |
| 1 | 3394983 | KIT-SPRING (Before Failure Only) |
| 1 | 3459194 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459195 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459213 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459215 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459216 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459218 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459219 | SOFTWARE GP-ELEK (Before Failure Only) |
| 1 | 3459220 | SOFTWARE GP-ELEK (Before Failure Only) |
| In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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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| Rework the fuel system. 1. Increase the fuel pump pressure by reworking the transfer pump and pressure regulating valve. 2. Replace the front supply fuel lines. - Engines in Group 1: Add rubber grommeted clips. - Engines in Group 2: Only replace hoses. 3. Update the engine software. Refer to the attached Rework Procedure. Note: The front fuel hoses must be replaced on all engines on this service letter. Cavitation erosion has been known to damage the interior of the hose assembly. This damage is not externally observable. Note: Do not use Caterpillar HIS Information to fabricate the 322-7616 hoses. These hoses must be purchased from the Caterpillar Parts System as complete assemblies. |
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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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| *******Group 1******* | |||||
| NOTE: This is a 4.5-hour job for Group 1 | |||||
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| *******Group 2******* | |||||
| NOTE: This is a 4.5-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 REWORKING THE FUEL SYSTEM ON CERTAIN C27 AND C32 ELECTRIC POWER GENERATION UNITS OPERATING IN PRIME OR CONTINUOUS ENVIRONMENTS MODELS INVOLVED - C27 and C32 ELECTRIC POWER GENERATION UNITS Dear Caterpillar Product Owner: The fuel system needs to be reworked on the products listed below. The existing front fuel supply hoses may not reach full life on engines operating in a prime or continuous environment. 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 07Sep2010 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 07Sep2010 Service Letter |
| Group Number 1 |
| NOTE: Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated. Use caution to ensure that no dirt enters the fuel port in the cylinder head. Damage to the fuel injectors could result. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTE: Download the appropriate software as indicated by referencing the chart below (Image 1.1.1). If a given engine's software is not listed in this table, please refer to SISWEB or TMI for the latest available software. 1. Download the appropriate software prior to beginning the rework. |
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| Image1.1.1 |
| 2. Remove the existing front supply fuel hoses (2), standpipe port connectors (2) and hardware. Retain all mounting for reuse. Inspect the fuel hoses for chafing/abrasion damage. If observed, be sure to correct the issue when installing the new fuel hoses later. Pressure pulsations in these hoses cause them to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak. |
| 3. Remove the 228-7381 Check Valve Group in the fuel return manifold (B), and replace with the 327-4448 Check Valve Group. Refer to Image1.3.1. 4. Remove the fuel transfer pump (A) located next to the fuel return manifold (B) as shown in Image1.3.1. |
 |
| Image1.3.1 |
| 5. Remove the Spring kit from the pump. Install the 339-4983 Spring Kit into the fuel transfer pump. Refer to Image1.4.1. The transfer pump has the old part number. By installing the 339-4983 Spring Kit, the pump has been upgraded to the new 331-3635 Transfer Pump. Mark the upgraded fuel pump with the new part number for later identification. |
 |
| Image1.4.1 |
| 6. Reinstall the fuel transfer pump using a new 8C-3089 O-ring. |
| 7. Remove existing port connector from the right side cylinder head and replace with new 147-3396 connector and 214-7568 O-ring seal. Tighten the connector to a torque of 34 +/- 3 N*m (25 +/- 2 lb ft). Install the right front fuel hose using a new 322-7616 Hose. The existing P-clip should be replaced with a rubber grommeted clip. Install a new 7V-6571 rubber grommet using an 8T-1889 and 8T-1890 two-piece clip mounted with existing bolt, washer, and spacer. Install clip mounted upward. Opening in the grommet must line up between gap in the 8T-1889 and 8T-1890 clips. Connect the 322-7616 fuel hose to the port connector and the tee, and tighten both ends to a torque of 27 +/- 6 N*m (20 +/- 4 lb ft). NOTE: Ensure the hoses do not contact nearby parts. Pressure pulsations in these hoses cause them to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak. Note: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure. Note: No cable tie fastening is allowed. |
 |
| Image1.6.1 |
| 8. Remove existing port connector from the left side cylinder head and replace with new 147-3396 connector and 214-7568 O-ring seal. Tighten the connector to a toque of 34 +/- 3 N*m (25 +/- 2 lb ft). Install the left front fuel hose using a new 322-7616 Hose. The existing P-clip should be replaced with a rubber grommeted clip. Install a new 7V-6571 rubber grommet using an 8T-1889 and 8T-1890 two-piece clip mounted with existing bolt and washer. Install clip mounted upward. Opening in the grommet must line up between gap in the 8T-1889 and 8T-1890 clips. Connect the 322-7616 fuel hose to the port connector and the tee and tighten both ends to a torque of 27 +/- 6 N*m (20 +/- 4 lb ft). NOTE: Ensure that the hoses do not contact nearby parts. Pressure pulsations in these hoses cause them to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak. NOTE: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure. NOTE: No cable tie fastening is allowed. |
 |
| Image1.7.1 |
| Group Number 2 |
| NOTE: Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated. Use caution to ensure that no dirt enters the fuel port in the cylinder head. Damage to the fuel injectors could result. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTE: Download the appropriate software as indicated by referencing the chart below (Image 2.1.1). If a given engine's software is not listed in this table, please refer to SISWEB or TMI for the latest available software. 1. Download the appropriate software prior to beginning the rework. |
 |
| Image2.1.1 |
| 2. Remove the existing front supply fuel hoses (2). Retain all hardware for reuse. Inspect the fuel hoses for chafing/abrasion damage. If observed, be sure to correct the issue when installing the new fuel hoses later. Pressure pulsations in these hoses cause them to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak. |
| 3. Remove the 228-7381 Check Valve Group in the fuel return manifold (B), and replace with the 327-4448 Check Valve Group. Refer to Image2.3.1. 4. Remove the fuel transfer pump (A) located next to the fuel return manifold (B) as shown in Image2.3.1. |
 |
| Image2.3.1 |
| 5. Remove the Spring kit from the pump. Install the 339-4983 Spring Kit into the fuel transfer pump. Refer to Image2.4.1. The transfer pump has the old part number. By installing the 339-4983 Spring Kit, the pump has been upgraded to the new 331-3635 Transfer Pump. Mark the upgraded fuel pump with the new part number for later identification. |
 |
| Image2.4.1 |
| 6. Reinstall the fuel transfer pump using a new 8C-3089 O-ring. |
| 7. Install the right front fuel hose using a new 322-7616 Hose. The existing mounting hardware, rubber grommeted clips, and brackets should be reused. Openings in the grommets must line up between gap in the 8T-1889 and 8T-1890 clips. Connect the 322-7616 fuel hose to the port connector and the tee and tighten both ends to a torques of 27 +/- 6 N*m (20 +/- 4 lb ft). NOTE: Ensure the hoses do not contact nearby parts. Pressure pulsations in these hoses cause them to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak. NOTE: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure. NOTE: No cable tie fastening is allowed. |
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| Image2.6.1 |
| 8. Install the left front fuel hose using a new 322-7616 Hose. The existing mounting hardware, rubber grommeted clips, and brackets should be reused. Openings in the grommets must line up between gap in the 8T-1889 and 8T-1890 clips. Connect the 322-7616 fuel hose to the port connector and the tee and tighten both ends to a torque of 27 +/- 6 N*m (20 +/- 4 lb ft). NOTE: Ensure that the hoses do not contact nearby parts. Pressure pulsations in these hoses cause them to flex. Inadvertent contact with nearby surfaces will produce chafing/abrasion damage that could eventually lead to a leak. NOTE: If a metal part number tag is present, it must be removed after connecting the fuel hose. Failure to remove this metal tag can result in hose failure. NOTE: No cable tie fastening is allowed. |
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| Image2.7.1 |
Caterpillar Information System:
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING PRINTED CIRCUIT BOARDS ON CERTAIN FLYWHEEL UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, AND UPS 900 UNINTERRUPTIBLE POWER SUPPLIES PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING PRINTED CIRCUIT BOARDS ON CERTAIN FLYWHEEL UPS 250, UPS 300, UPS 301, UPS 500, UPS 600, AND UPS 900 UNINTERRUPTIBLE POWER SUPPLIES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 114-1142 AND 128-8065 CIRCUIT BREAKERS ON CERTAIN C27 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REPLACING THE 114-1142 AND 128-8065 CIRCUIT BREAKERS ON CERTAIN C27 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER ASSEMBLY (CAC) ON CERTAIN C27 AND C32 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE CHARGE AIR COOLER ASSEMBLY (CAC) ON CERTAIN C27 AND C32 GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER BASE MOUNTING BRACKET ON CERTAIN RIGHT HAND SERVICE C32 ACERT MARINE ENGINES PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER BASE MOUNTING BRACKET ON CERTAIN RIGHT HAND SERVICE C32 ACERT MARINE ENGINES
PRODUCT SUPPORT PROGRAM FOR REWORKING THE 299-5886 SUPPORT PLATE FOR THE VOLTAGE REGULATOR ON CERTAIN C2.2, C3.3, C4.4, AND C6.6 POWERED GENSETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE 299-5886 SUPPORT PLATE FOR THE VOLTAGE REGULATOR ON CERTAIN C2.2, C3.3, C4.4, AND C6.6 POWERED GENSETS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL LEVEL SENDER ON CERTAIN C2.2 AND C6.6 GENSETS PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL LEVEL SENDER ON CERTAIN C2.2 AND C6.6 GENSETS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE LOW COOLANT LEVEL SENSOR ON CERTAIN C1.5, C2.2, C3.3, C4.4, AND C6.6 GENSETS PRODUCT SUPPORT PROGRAM FOR REPLACING THE LOW COOLANT LEVEL SENSOR ON CERTAIN C1.5, C2.2, C3.3, C4.4, AND C6.6 GENSETS
PRODUCT SUPPORT PROGRAM FOR INSTALLING THE MISSING ADAPTER PLATE ON CERTAIN C1.5 AND C2.2 GENSET CONTROL PANELS PRODUCT SUPPORT PROGRAM FOR INSTALLING THE MISSING ADAPTER PLATE ON CERTAIN C1.5 AND C2.2 GENSET CONTROL PANELS
PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ECM SOFTWARE ON CERTAIN 630HP AND 700HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL PRODUCT SUPPORT PROGRAM FOR FLASHING NEW ENGINE ECM SOFTWARE ON CERTAIN 630HP AND 700HP C18 INDUSTRIAL ENGINES LOCATED IN COUNTRIES WITH LOW REGULATED FUEL
PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER HEATER CIRCUIT BREAKER ON CERTAIN C9 GENSETS PRODUCT SUPPORT PROGRAM FOR REPLACING THE JACKET WATER HEATER CIRCUIT BREAKER ON CERTAIN C9 GENSETS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE SOUND INSULATION FOAM IN THE CANOPY OUTLET BOX ON CERTAIN C2.2 RENTAL GENSETS PRODUCT SUPPORT PROGRAM FOR REWORKING THE SOUND INSULATION FOAM IN THE CANOPY OUTLET BOX ON CERTAIN C2.2 RENTAL GENSETS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN ROCKER SWITCHES FROM DEALER PARTS STOCK PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN ROCKER SWITCHES FROM DEALER PARTS STOCK
PRODUCT SUPPORT PROGRAM FOR REWORKING THE ASR RELAY ON CERTAIN PM3516, XQ2000 POWER MODULES WITH AUTO PARALLELING CONTROLS PRODUCT SUPPORT PROGRAM FOR REWORKING THE ASR RELAY ON CERTAIN PM3516, XQ2000 POWER MODULES WITH AUTO PARALLELING CONTROLS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE FUEL LINE ON CERTAIN C6.6 ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE HIGH PRESSURE FUEL LINE ON CERTAIN C6.6 ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE TEMPERATURE SENDER ON CERTAIN C6.6 ENGINES IN XQ175 GENSETS PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE TEMPERATURE SENDER ON CERTAIN C6.6 ENGINES IN XQ175 GENSETS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 275-5519 CARRIER ASSEMBLY ON CERTAIN CX31 ON-HIGHWAY TRANSMISSIONS PRODUCT SUPPORT PROGRAM FOR REPLACING THE 275-5519 CARRIER ASSEMBLY ON CERTAIN CX31 ON-HIGHWAY TRANSMISSIONS
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 7C7677 AND 7C7678 FUEL LINE TUBES FROM DEALER PARTS STOCK PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 7C7677 AND 7C7678 FUEL LINE TUBES FROM DEALER PARTS STOCK
PRODUCT SUPPORT PROGRAM FOR REWORKING THE 217-8464 LEVEL ALARM GROUP ON CERTAIN 3616 AND C280-16 ENGINES PRODUCT SUPPORT PROGRAM FOR REWORKING THE 217-8464 LEVEL ALARM GROUP ON CERTAIN 3616 AND C280-16 ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER WASTEGATE CANISTER ON CERTAIN C13 INDUSTRIAL ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER WASTEGATE CANISTER ON CERTAIN C13 INDUSTRIAL ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT EXPANSION TANK HOSE, HOSE CONNECTOR, AND CLAMPS ON CERTAIN C2.2, C4.4, AND C6.6 GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REPLACING THE COOLANT EXPANSION TANK HOSE, HOSE CONNECTOR, AND CLAMPS ON CERTAIN C2.2, C4.4, AND C6.6 GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION OF THE FRONT GEAR TRAIN BOLTS ON CERTAIN C175-16 GENSETS PRODUCT IMPROVEMENT PROGRAM FOR INSPECTION OF THE FRONT GEAR TRAIN BOLTS ON CERTAIN C175-16 GENSETS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE BREAKER ON CERTAIN CAT SWITCHGEAR PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPAIRING THE BREAKER ON CERTAIN CAT SWITCHGEAR
PRODUCT SUPPORT PROGRAM FOR MODIFICATIONS IN THE SWING PILOT CIRCUIT IN ORDER TO PREVENT JOYSTICK VIBRATION ON CERTAIN 345D EXCAVATORS PRODUCT SUPPORT PROGRAM FOR MODIFICATIONS IN THE SWING PILOT CIRCUIT IN ORDER TO PREVENT JOYSTICK VIBRATION ON CERTAIN 345D EXCAVATORS
PRODUCT IMPROVEMENT PROGRAM FOR PROVIDING ELECTRICAL INTERLOCK FOR DUAL AIR SHUTOFF CONFIGURATION ON CERTAIN PETROLEUM C32 GENERATOR SETS ORDERED FROM THE ELECTRIC POWER PRICELIST PRODUCT IMPROVEMENT PROGRAM FOR PROVIDING ELECTRICAL INTERLOCK FOR DUAL AIR SHUTOFF CONFIGURATION ON CERTAIN PETROLEUM C32 GENERATOR SETS ORDERED FROM THE ELECTRIC POWER PRICELIST