PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL FILTER SYSTEM ON CERTAIN C7.1 INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL FILTER SYSTEM ON CERTAIN C7.1 INDUSTRIAL ENGINES

Usage:

REBE9743-00

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30Jul2013

U-338

O-286

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL FILTER SYSTEM ON CERTAIN C7.1 INDUSTRIAL ENGINES
1274		PS43972

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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 "PS43972" 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

31Jul2015

PROBLEM

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The existing on engine fuel filter system was shipped with the engines. The engines were ordered with an off engine fuel filter system on certain C7.1 Industrial Engines.

AFFECTED PRODUCT

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Model	Identification Number
C7.1	77000252, 255, 299-311, 350-354, 384-391, 397-400, 402, 406-407, 410-411, 413-414, 421

PARTS NEEDED

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Qty	Part Number	Description
1	KIT	FUEL FILTER KIT (See Action Required)
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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Send an email to Janne Tuominen for ordering parts for this program. Refer to the following contact information:

Janne Tuominen
Wihuri Oy Technical Trade / Witraktor
Kiitoradantie 4
01511 Vantaa, Finland
Email: janne.tuominen@wihuri.fi
Tel: +358 20 510 2585

This rework must be executed as a joint collaboration between Sandvik and Cat dealers.

This rework incorporates the Cat Dealer installing the engine remote fuel system and the Sandvik Dealer installing relevant brackets and machine components as controlled by Sandvik.

Remove the on engine fuel filter system and replace with an off engine fuel filter system.

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%
0-4500 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 5.0-hour job

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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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This data was taken from 'Sandvik C7.1 Remote filter kit: Field installation' by Janne Ojanper? from Wihuri Oy Witraktor Power Systems dated 24th October 2012.

1 Preparation
1.1 Battery switch and fuel valves
Refer to Image 1.2.1 - Before any other procedures, disconnect battery cables or turn battery switch off (green). Then close the ball valves of fuel lines at the backside of fuel tank (yellow). If there is no valve in return line, loose hose connection of the tank to stop the siphoning.

1.2 Belt and Bottom covers
Refer to Image 1.2.2 - Remove Bottom plate by opening following bolts. Note that the weight of plate is 18Kgs. Please review safety requirements before removal.
Refer to Image 1.2.3 - Disconnect electrical connector of AC-compressor (yellow) and cut cable ties of harness. Open lower bolts of belt cover.
Refer to Image 1.2.4 - Open upper bolts and remove belt cover.

1.3 Contamination control
When covers are removed clean engine and everything around it very careful with steam cleaner or pressure cleaner. Before attempting any work on fuel system ensure that engine is cleaned of any dirt that might contaminate the fuel system.
It is mandatory that you seal all fuel connections and charge air pipes with clean plastic caps immediately when opened.
All new components should remain bagged and capped until immediately before use.

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2 Removing the original system
2.1 Aftercooler to engine pipe
Refer to Image 1.3.1 - Open both clamps and remove silicon hose. Install cap to intake manifold connection.
Refer to Image 1.3.2 - Open clamp of lower ATAAC connection and install cap to the ATAAC outlet.
Refer to Image 1.3.3 - Open pipe support clamp which is installed below radiator and then remove ATAAC pipe.

2.2 Electrical harness
Refer to Image 1.3.4 - Disconnect CAC outlet temperature sensor connector (blue), open harness brackets (red). You can also cut cable ties to make as much free space around filter as possible.

2.3 Transfer pump fuel hose
Refer to Image 1.3.5 - Open hose support bracket and remove hose between fuel transfer pump and secondary filter. Seal connections with caps.

2.4 Secondary filter
Refer to Image 1.3.6 - Open all remain fuel pipe connectors from filter and install caps and plugs to connections. Open flanged bolts and remove secondary filter unit.

2.5 Fuel pipes and pipe supports
Refer to Image 1.3.7 - Disconnect steel line connection of vent line and seal connections with caps.
Refer to Image 1.3.8 - Disconnect vent line connector of HP fuel pump. Seal connections with caps.
Refer to Image 1.3.9 - Disconnect connector of Common rail pressure limiting valve. Seal connections with plastic caps.
Refer to Image 1.3.10 - Remove fuel pipe support bracket at the left side of the engine.
Refer to Image 1.3.11 - Disconnect fuel pipe connector from ECM. Seal connections and remove fuel pipe.
Refer to Image 1.3.12 - Disconnect connectors of the regulator return line hose and clean line pipe (red). Seal connections with caps. Open bolt of pressure regulator (blue). Now remove vent line pipe and clean fuel pipe. Cut harness cable ties, open filter bracket bolts and remove bracket.
Refer to Image 1.3.13 - Remove stud bolts of secondary filter bracket.

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3 Installing remote filter system
3.1 Secondary filter
Refer to Image 1.4.1 - Fit secondary filter to bracket using M10 bolts, nuts and washers supplied by Sandvik.

3.2 Fuel pipe support brackets
Refer to Image 1.4.2 - Fit vent line support bracket with two flanged bolts (M8) to the left side of the engine.
Refer to Image 1.4.3 - Fit support line bracket with two M8 flanged bolts.
Refer to Image 1.4.4 - Fit regulator bracket to the cylinder head using two M8 flanged bolts.

3.3 Fuel lines
Refer to Image 1.4.5 - Fit line from secondary filter head to fuel pump. Fit regulator to the regulator support bracket using M6 flanged bolt. Fit the P-clip secure the line to the regulator bracket using M8 flanged bolt.
If coolant hose (arrow) is fitted with straight connection drain coolant and open it.
Refer to Image 1.4.6 - Fit 90 degree elbow to coolant connection supplied by Sandvik and fit return line to regulator.
Refer to Image 1.4.7 - Attach vent line to steel line connection.
Refer to Image 1.4.8 - Fit vent line to HP fuel pump return connection. Clip the line at four points to the support brackets.
Refer to Image 1.4.9 - Attach vent line to common rail pressure limiting valve.
Refer to Image 1.4.10 - Fit the P-clip support to the vent line bracket using M8 flanged bolt.

3.4 Fuel hoses
Refer to Image 1.4.11 - Route the clean fuel hose as shown
Refer to Image 1.4.12 - Attach hose from ECM outlet to secondary filter in. Elbow and hose supplied by Sandvik.
Refer to Image 1.4.13 - Route ECM to Secondary filter hose under the radiator.
Refer to Image 1.4.14 - Fit clean hose to secondary filter outlet. Then fit ECM to secondary filter hose to the secondary filter inlet.
Fit hose from transfer pump to secondary filter in (arrow). Hose supplied by Sandvik.
Refer to Image 1.4.15 - Attach secondary filter vent line hose to engines vent line piping. Hose supplied by Sandvik.
Route hose to secondary filter under the radiator.
Refer to Image 1.4.16 - Fit vent line hose to secondary filter venting connector.

3.5 Aftercooler to engine pipe
Refer to Image 1.4.17 - Fit new CAC to intake manifold pipe and new silicon hoses supplied by Sandvik.
Refer to Image 1.4.18 - Use original pipe support bracket.

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4 Finishing installation
4.1 Harness and connectors
Refer to Image 1.5.1 - Use original cable tie fitting from original secondary filter bracket. Fit harness with cable ties.
Refer to Image 1.5.2 - Use cable ties and straps to fit harness and hoses. Fit connector of ATAAC to engine temp sensor.