PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL SYSTEM ON CERTAIN D10N AND D10R TRACK-TYPE TRACTORS WITH RETROFIT C27 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL SYSTEM ON CERTAIN D10N AND D10R TRACK-TYPE TRACTORS WITH RETROFIT C27 ENGINES

Usage:

REBE6745-01

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07Jan2011

(Revised 24Jan2011)

U-15

D-15

O-15

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING THE FUEL SYSTEM ON CERTAIN D10N AND D10R TRACK-TYPE TRACTORS WITH RETROFIT C27 ENGINES
1274 1250		PI31833

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31833" 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 "PI31833" 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 07Jan2011 Service Letter. Changes have been made to Affected Product.

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COMPLETION DATE	TERMINATION DATE
31Jul2011	31Jan2012

PROBLEM

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The fuel lines can fail and leak fuel on certain D10N and D10R track-type tractors.

AFFECTED PRODUCT

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Model	Identification Number
D10N	2YD00505, 857, 1463, 1536, 1554, 2015, 2093, 2375, 2443, 2489, 75326 3SK00777, 801, 982, 1097
D10R	3KR00575, 1399, 1419, 1460, 1565, 1840

PARTS NEEDED

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Qty	Part Number	Description
2	0L1352	BOLT
2	0S1571	BOLT
1	2M9780	SEAL-O-RING
6	5M2894	WASHER-HARD
1	7J9108	SEAL-O-RING-ORFS
1	8C3089	SEAL-O-RING
1	8T1576	ADAPTER-STR
2	9S8752	NUT-FULL
1	3227615	HOSE AS.
2	3227616	HOSE AS.
1	3227617	HOSE AS.
1	3274448	VALVE GP-CHECK-A
1	3394983	KIT-SPRING
2	3527474	BRACKET
1	3655929	SOFTWARE GP-ELEK (Use with the 328-1711 Engine Ar)
1	3655930	SOFTWARE GP-ELEK (Use with the 316-9147 Engine Ar)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% 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 specified existing fuel lines.

3. Update the software for proper operation of the filter restriction warning.

4. Remove and replace the check valve at the fuel priming pump outlet with a connector to lower the system restriction at the fuel transfer pump inlet.

Refer to the attached Rework Procedure.

NOTE: The fuel hoses must be replaced. 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 322-7615, 322-7616, and 322-7617 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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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 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.

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 D10N AND D10R TRACK-TYPE TRACTORS WITH RETROFIT C27 ENGINES

MODELS INVOLVED - D10N and D10R track-type tractors

Dear Caterpillar Product Owner:

The fuel system needs to be reworked on the products listed below. The existing fuel lines can leak. 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 07Jan2011 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 07Jan2011 Service Letter

Rework Procedure

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NOTE:
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: Multiple service letters have been issued to upgrade the fuel lines. This rework procedure is dependent upon proper completion of those letters. Refer to the latest change to the 312-5582 Lines Group Fuel in SISWEB.

NOTE: Download the 365-5930 Software Group Electronic for D10N with the 316-9147 Engine Arrangement. Download the 365-5929 Software Group Electronic for D10R with the 328-1711 Engine Arrangement. The engine arrangement can be found on the serial number plate of the engine. Download the appropriate software prior to beginning the rework.

1. Park the machine in accordance with the Operation and Maintenance Manual. Turn off the fuel valve (V) at the tank. See Image 1.1.1.

2. Remove the 9W-1599 Check Valve (X) and the mating O-rings near the fuel water separator. See image 1.1.1. Install the 8T-1576 Connector, 7J-9108, and 2M-9780 Seal O-rings in place of the check valve.

Image1.1.1

Image1.1.2

3. Clearly identify that the port for fuel entry into each cylinder head uses the 1P-1376 Port Connector and the 214-7568 O-ring. The height of the port connector is less than 50 mm (2 in.) tall when installed in the head. Prior port connectors are much taller. Taller port connectors will cause the hose to be too long and will not route properly. If this work was not performed on a prior service letter, ensure that these port connectors are replaced. Refer to the latest change to 312-5582 Lines Group-Fuel in SISWEB.

Image1.1.2 shows a typical straight hose end fitting with a 1P1376 Port Connector.

NOTE: Picture is incomplete because some components have been removed for clarity.

4. Remove the 322-7615, 322-7616, and 322-7617 fuel lines, brackets, and hardware. Retain all hardware because it will be reinstalled later. 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.

Image1.3.1

5. 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.

6. Remove the fuel transfer pump (A) located next to the fuel return manifold (B) as shown in Image1.3.1.

Image1.4.1

7. 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.

Image1.5.1

8. Reinstall the fuel transfer pump using a new 8C-3089 O-ring.

9. Install the two rear fuel hoses using new hoses. Note that the left side hose part number is 322-7615 and the right side hose part number is 322-7617. The clipping and routing of these hoses remains unchanged. Image1.7.1 shows the left side and Image1.7.2 shows the right.

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.

Image1.7.1

Image1.7.2

10. Install the right front fuel hose using a new 322-7616 Hose. All clip points and hose routing remain unchanged except the the 6L-2479 Angle Bracket is replaced by the 352-7474 Bracket. Install the new 352-7474 bracket (1) using the 0L-1352 Bolt (2) and 5M-2894 Washer (3). Reinstall the harness ladder clip with the two piece p-clip using the 0S-1571 Bolt, 9S-8752 Nut, and two 5M-2894 Washers (D). Angle the harness ladder clip downward. Ensure the harness is tie wrapped to the harness ladder clip. Refer to Image1.8.1 for proper orientation of the bracket and p-clip. This is a view looking from the front of the engine.

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.

Image1.8.1

11. Install the left front fuel hose using a new 322-7616 Hose. All clip points and hose routing remain unchanged except the 352-7474 Bracket replaces the 6L-2479 Angle Bracket. Install the 352-7474 Bracket (1) using the 0L-1352 Bolt (2) and 5M-2894 Washer (3). Assemble the two piece p-clip to the new bracket using a 0S-1571 Bolt, 9S-8752 Nut, and two 5M-2894 Washers (D). Refer to Image1.9.1 for proper orientation of the bracket and p-clip. This is a view looking towards the side of the engine.

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.

Image1.9.1

12. Copy the engine configuration using Cat ET to allow it to be copied to the engine ECM after flashing. Flash the appropriate engine software from SISWEB using CAT ET for machines equipped with the Air-To-Air Aftercooler (ATAAC).

If the machine has 316-9147 Engine Arrangement, use the 365-5930 Software Group Electronic.
If the machine has 328-1711 Engine Arrangement, use the 365-5929 Software Group Electronic.

NOTE: Ensure the engine configuration is copied from the Engine Electronic Control Module (ECM) before flashing software.

13. Copy the engine configuration file to the engine ECM.

14. Turn on the fuel valve (V) at the tank (Image1.1.1). Prime fuel system using the electric fuel priming pump. Check for any leaks.

15. Start engine and verify operation of the engine and machine. Check for leaks and hose rubs. Adjust clips as needed to ensure hoses do not contact surrounding surfaces.