PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL PRESSURE REGULATING MANIFOLD ON CERTAIN C32 MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL PRESSURE REGULATING MANIFOLD ON CERTAIN C32 MARINE ENGINES

Usage:

TEBE1872-00

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31Oct2014

U-637

D-568

O-555

TM-25

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL PRESSURE REGULATING MANIFOLD ON CERTAIN C32 MARINE ENGINES
1274		PI32405

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI32405" 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 "PI32405" 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
30Apr2015	31Oct2015

PROBLEM

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The fuel pressure regulating manifold needs to be replaced on certain C32 Marine Engines. The existing fuel pressure regulating manifold can leak fuel.

AFFECTED PRODUCT

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Model	Identification Number
C32	RSD00214, 223-238 RTK00122 SDN00468, 470-471, 477, 479-480, 482, 485-491, 494, 496, 500, 502

PARTS NEEDED

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Qty	Part Number	Description
2	2R6806	ADAPTER-STR
2	6D7146	SEAL-O-RING
1	1184728	ADAPTER-ELBOW
2	2147568	SEAL-O-RING-STOR
1	2385080	SEAL-O-RING-STOR
2	3274448	VALVE GP-CHECK-A
1	3343807	MANIFOLD
2	3638595	SEAL-INTEGRAL
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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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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Owners in the following countries will receive the attached Owner Notification:
US
Canada

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 2.5-hour job
Travel will only be authorized for one engine for multiple engines being reworked in a boat. Please reference the other engine serial numbers in the claim story. There is a $30 miscellaneous allowance for purchase of paint to match the engine. There is a $30 miscellaneous allowance for purchse of 30 cm of SOLAS tape (if required by Marine Classification Society).

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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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EXAMPLE COPY OF OWNER NOTIFICATION

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL PRESSURE REGULATING MANIFOLD ON CERTAIN C32 MARINE ENGINES

MODELS INVOLVED - C32 MARINE ENGINES

Dear Cat Product Owner:

The fuel pressure regulating manifold needs to be replaced on the products listed below. The existing fuel pressure regulating manifold can leak fuel. You will not be charged for the service performed.

Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 31Oct2014 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 31Oct2014 Service Letter

Rework Procedure

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Before completing the attached Rework Procedure, please review the safety actions in the Operation and Maintenance Manual for the engine.

Caution:
Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while performing work on the fuel system.

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.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Steps 1-4 may be carried out prior to traveling to engine.

Step 1: Install 118-4728 Adapter-Elbow and 238-5080 Seal into the 334-3807 Manifold shown as Item 1 in Image 1.1.1. Tighten the connection to a torque of 80 Nm (59 ft-lbs).

Step 2: Install two 2R-6806 Adapters and two 214-7568 Seals into the 334-3807 Manifold shown as Items 2 in Image 1.1.1. Tighten connections to a torque of 40 Nm (25 ft-lbs).

Step 3: Install two 327-4448 Valve Gp-Checks into the 334-3807 Manifold shown as Item 3 in Image 1.1.1. Tighten check valves to a torque of 28 Nm (20 ft-lbs). NOTE: Over tightening these valves can cause the valve to stick later resulting in high or low fuel pressure when installed on engine.

Step 4: Mask and paint block to match engine.

Image1.1.1

Step 5: Remove the 363-0190 Elbow and 363-0191 Elbow, shown as Items 1 and 2 respectively in Image 1.2.1, to gain access to the 334-3807 Manifold shown as Item 3 in Image 1.2.1.

Image1.2.1

Step 6: Remove the left hand side air cleaner shown as Item 4 in Image 1.3.1.

Image1.3.1

Step 7: Remove the 364-8679 Line As-Hybrid shown as Item 5 in Image 1.4.1.

Image1.4.1

Step 8: Disconnect the 371-5633 Line As-Hybrid and 365-0746 Line As-Hybrid from the 334-3807 Manifold shown as Items 6 and 7 respectively in Image 1.5.1.

Step 9: Replace the existing 334-3807 Manifold with the new 334-3807 Manifold and fittings assembled in Steps 1-4.

Step 10: Reconnect the 371-5633 Line As-Hybrid and 365-0746 Line As-Hybrid to the 334-3807 Manifold shown as Items 6 and 7 respectively in Image 1.5.1. Tighten the line assemblies to a torque of 30 Nm (22 ft-lbs).

Image1.5.1

Step 11: Reinstall the 364-8679 Line As-Hybrid shown as Item 5 in Image 1.4.1 between the fuel pressure regulating manifold and fuel cooler. Tighten the fuel line connections to a torque of 60 Nm (44 ft-lbs).

Step 12: If required by Marine Classification Society apply 10 cm of SOLAS tape on each of the two connections made on the fuel pressure regulating manifold and to the fuel line connection at the fuel cooler.

Step 13: Reinstall the left hand side air cleaner shown as Item 4 in Image 1.3.1.

Step 14: Reinstall the 363-0190 Elbow with a new 363-8595 Seal-Integral and 6D-7146 Seal shown as Item 1 in Image 1.2.1.

Step 15: Reinstall the 363-0191 Elbow with a new 363-8595 Seal-Integral and 6D-7146 Seal shown as Item 2 in Image 1.2.1.

Step 16: If necessary prime the fuel system.