PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL INJECTION NOZZLES AND INSTALLING AN ADDITIONAL FUEL FILTER ON CERTAIN 320D EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL INJECTION NOZZLES AND INSTALLING AN ADDITIONAL FUEL FILTER ON CERTAIN 320D EXCAVATORS

Usage:

REBE4232-00

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16Feb2009

D-54

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE FUEL INJECTION NOZZLES AND INSTALLING AN ADDITIONAL FUEL FILTER ON CERTAIN 320D EXCAVATORS
1254 1261 1290		PS42882

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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 "PS42882" 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

28Feb2011

PROBLEM

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The existing machines with Tier-2 emission engines may have excess black smoke on certain 320D Excavators. If the existing injector fails, it may cause blowing of black smoke during machine operation with some load factor.

AFFECTED PRODUCT

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Model	Identification Number
320D	JGZ00151-00417, 489-560, 562-739, 741-830, 880-1121, 1124-1162
320D L	MDE00114-00123, 189-193, 248-249, 255-259, 266-270, 276-278, 332-336, 342-346, 352-353, 374-378, 395-398, 403-407, 414-417, 422-426, 433-436, 441-445, 452-455, 460-464, 471-474, 479-483, 566-569, 574-618, 679-682, 687-690, 695-700, 704-711, 804-808, 813-816, 821-825, 830-835, 840-845, 850-853, 858, 863-864, 873-874, 883-884, 893-894, 903-904, 913-914, 923-925, 934-936, 945-947, 956-958, 967-968, 987, 992, 997-998, 1003-1004, 1009, 1014, 1019-1020, 1025-1026, 1031, 1034-1036, 1039-1042, 1045-1048, 1051-1063, 1068-1069, 1074-1075, 1080-1081, 1086-1087, 1092-1093, 1098-1099, 1104-1105, 1110-1111, 1116-1117, 1122-1123, 1130-1159, 1163-1164, 1168-1170, 1175-1176, 1181, 1186-1187, 1192-1193

PARTS NEEDED

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Qty	Part Number	Description
1	5C2890	NUT-HEX
146	7I7439	GUARD-BULK
1	7X2533	BOLT
1	7X2535	BOLT
2	8T3597	NUT-WELD
2	8T4121	WASHER-HARD
2	8T4182	BOLT-HEX HEAD
3	9X8256	WASHER
4	0994437	GASKET
2	1358573	BOLT AS-SPL
1	1968236	FILTER AS
2	2941831	CLAMP
1	2941833	CLAMP
1	3054887	HOSE
1	3054888	HOSE
1	3244077	PLATE
1	3244078	SUPPORT AS
6	3244086	NOZZLE AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% 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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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%
0-5000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-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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1. Replace the fuel injection nozzles with new fuel injection nozzles. Refer to Disassembly and Assembly Manual, SENR5553.

Install the additional filter, follow the steps below.

2. Remove two 135-8573 Bolts, two 135-8575 Bolts and two 170-3016 Spacers from 268-0555 Hood Group in order to remove the 244-8212 Cover Assembly.

Image1.2.1

3. Rework the 244-8212 Cover Assembly. Refer to attach images below.

Image1.3.1

4. Remove two clamps for the air intake hose and pull off the two air intake hoses from 244-8226 Support Assembly.

Image1.4.1

5. Remove two 135-8573 Bolts from the 268-0555 Hood Group, and remove the 244-8226 Support Assembly.

Image1.5.1

6. Rework the 244-8226 Support Assembly. Refer to the attached images.

Image1.6.1

7. Remove four 135-8573 Bolts from the 268-0555 Hood Group. Remove the 262-2340 Sheet Assembly.

Image1.7.1

8. Rework the 262-2340 Sheet Assembly. Refer to the attached images.

Image1.8.1

10. Attach the 324-4078 Support Assembly to the 262-2340 Sheet Assembly. Use two 135-8573 Bolts and tighten the bolts to a torque of 60+/-10 Nm.

Image1.9.1

11. To attach the 262-2340 Sheet Assembly to the 268-0555 Hood Group, use the four 135-8573 Bolts from Step-7. Tighten the bolts to a torque of 100+/-20 Nm.

12. To attach the 244-8226 Support Assembly to the 268-0555 Hood Group, use the two 135-8573 Bolts from Step-5. Tighten the bolts to a torque of 100+/-20 Nm.

13. To attach the 196-8236 Filter Assembly to the 244-8226 Support Assembly, use the two 8T-4182 Bolts and two 8T-4121 Washers. Tighten the bolts to a torque of 32+/-3 Nm.

Image1.12.1

14. Remove the present fuel hose which connected between the outlet of the fuel priming pump and the inlet of present filter assembly.

Image1.13.1

15. Install the 099-4437 Gasket to both connectors on the 305-4888 Hose. Connect the 305-4888 Hose to the inlet of the new filter assembly using the 094-9726 Bolt and two 095-2040 Washers. Tighten the bolt to a torque of 34+/-4 Nm. Connect the other end of the 305-4888 Hose to the outlet of the fuel priming pump using the bolt and the washer of the priming pump. Tighten the bolt to a torque of 34+/-4 Nm.

16. Install the 7I-7439 Guard( Length is 700mm) to the 305-4888 Hose.

17. Install the 099-4437 Gasket to both connectors on the 305-4887 Hose. Connect the 305-4887 Hose to the outlet of the new filter assembly and inlet of the present filter assembly. Use the 094-9726 Bolt and two 095-2040 Washers in order to connect the hose to the filter assemblies. Tighten the bolts to a torque of 34+/-4 Nm.

18. Install the 7I-7439 Guard (Length is 760mm) to the 305-4887 Hose.

19. Tighten the 094-9725 Plug with the 095-2040 Washer on top of filter base of current fuel filter and additional fuel filter. Tighten the plug to a torque of 8.8+/-1 Nm.

Image1.18.1

20. Use the 294-1833 Clamp, 7X-2533 Bolt, and the 9X-8256 Washer in order to clamp the fuel hose. Tighten the bolt to a torque of 10+/-1 Nm.

Image1.19.1

21. Use two 294-1831 Clamps, 7X-2535 Bolt, two 9X-8256 Washers, and the 5C-2890 Nut in order to clamp the fuel hose. Tighten the bolt to a torque of 10+/-1 Nm.

22. Re-install the two air intake hoses, using the two 8T-4985 Clamps from Step-4. Tighten the clamps to a torque of 4.5+/-0.5 Nm.

Image1.21.1

23. Re-attach the 244-8212 Cover Assembly to the 268-0555 Hood Group. Use the two 135-8573 Bolts, two 135-8575 Bolts, and two 170-3016 Spacers from Step-2. Tighten the bolts to a torque of 100+/-20 Nm.