Usage:
Product Support Program For Replacing The Fuel Lines And/Or Brackets On Certain 3412 Generator Set, Industrial, And Marine Engines
| SMCS - | 1252 | PS4762 |
April 30, 1992
(Revised December 1992)
U-66
A-48
AU-44
B-28
E-39
O-55
TM-6
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.
NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4762" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use " T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use " Z" as the SIMS Description Code.
NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.
NOTE: This Revised Service Letter replaces the April 30, 1992 Service Letter. Group 4 Affected Product has been added. The Affected Product covered by Group 4 includes the identification numbers in Groups 1, 2, and 3 as well as additional serial numbers.
NOTE: Any Group 1, 2, or 3 Affected Product previously reworked under this Program needs to be reworked again as Group 4 Affected Product includes the latest changes.
Termination Date
April 30, 1993Problem
In some applications, the fuel lines may fail on certain 3412 Generator Set, Industrial, and Marine Engines.
Affected Product
Model & Identification Number
Group 1
3412 (5AG101-173; 7HG1-87; 60M3255-4497; 38S13772-15290; 81Z6748-11441)
Group 2
3412 (60M4498-4750; 38S15291-15648; 81Z11442-12567)
Group 3
3412 (60M4751-4896; 38S15649-15853; 81Z12568-13134)
Group 4
3412 (5AG101-173; 7HG1-87; 60M3255-5087, 60M5089; 38S13772-16396; 81Z6748-14183)
Parts Needed
Group 1
- 1 - 7C6589 Clamp
- 1 - 6I0349 Lines Group *
- 1 - 6I0350 Lines Group *
- 2 - 0L2070 Bolt
- 4 - 9N3388 Screw
- 5 - 0S1590 Bolt
- 3 - 8T1296 Washer
- 1 - 9Y3357 Clamp
- 7 - 9X6458 Washer
- 2 - 688438 Spacer
- 1 - 6I0349 Lines Group *
*Lines Groups are used only for this portion of the Program. These lines groups contain the new 4P7801 through 4P7812 Fuel Lines. Engines covered by Rework Procedures '2' and '3' already have the new lines groups. After the completion of this Program, lines groups will not be available in the parts system.
Additional parts needed for DIT (non-aftercooled) Engines
**Use in place of the 0L2070 and 051590 Bolts.
Group 2
- 2 - 7C6525 Clamp
- 1 - 7C7747 Clamp
- 1 - 6I4813 Clamp Kit *
- 2 - 0L2070 Bolt
- 5 - 9N3388 Screw
- 1 - 4P7137 Bracket
- 1 - 4P7144 Bracket
- 3 - 0S1590 Bolt
- 3 - 8T1296 Washer
- 2 - 1W9167 Clamp Assembly
- 1 - 1W9168 Clamp
- 1 - 1W9169 Clamp
- 5 - 9X6458 Washer
- 2 - 688438 Spacer
- 1 - 7C7747 Clamp
*Includes:
Additional parts needed for DIT (non-aftercooled) Engines
**Use in place of the 0L2070 and 0S1590 Bolts.
Group 3
Includes:
Parts needed for DIT (non-aftercooled) Engines
- 1 - 0L1351 Bolt**
**Use in place of the 0S1590 Bolt
Group 4
Action Required
Parts Stock
Remove all 7C6301, 7C6302, 7C6303, 7C6304, 7C6305, 7C6306, 7C6307, 7C6308, 7C6309, 7C6310, 7C6311, and 7C6312 Fuel Lines from parts stock.
Affected Product
See the appropriate Rework Procedure.
Service Claim Allowances
Parts Stock
Submit one claim for all 7C6301, 7C6302, 7C6303, 7C6304, 7C6305, 7C6306, 7C6307, 7C6308, 7C6309, 7C6310, 7C6311, and 7C6312 Fuel Lines removed from parts stock.
Affected Product
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
- (1 - Rework Procedure - Group 1)
- (2 - Rework Procedure - Group 2)
- (3 - Rework Procedure - Group 3)
- (4 - Rework Procedure - Group 4)
- (2 - Rework Procedure - Group 2)
Attach.
Rework Procedure - Group 1
1. Clean and pre-paint the new 6I0349 and 6I0350 Fuel Line Groups in your shop before proceeding to the job site.
NOTE: If the engine to be reworked is non-aftercooled, also clean and pre-paint the new 6I0348 Bracket Assembly.
A. Tape off the number 3, 5, and 6 fuel lines in the area of the tower clamp. (See Illustration 1, Section C-C).
Illustration 1
B. Make sure that the formed damper clamp for the number 4 and 6 fuel lines is close to the correct position and tape the fuel lines on each side of the damper clamp. (See Illustration 1, Section B-B).
C Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the fuel lines.
D Clean and paint the fuel line groups. If applicable, clean and pre-paint the 6I0348 Bracker Assembly.
E After drying completely, remove the tape. Do not remove the plastic caps and plugs until the fuel lines are ready to be installed on the engine.
2. Remove all the mounting bolts from the fuel line brackets at the aftercooler housing on DITA Engines or at the 9Y1112 Bracket Assembly on DIT Engines. Except for the tower clamp assembly, new mounting bolts and washers will be used. Keep the 9X6458 Washers, they may be needed as spacers.
NOTE: The 9Y1112 Bracket Assembly is the large bracket on DIT (non-aftercooled) Engines used to support the fuel line brackets. This bracket is part of the 6N5140 Fastener Group.
NOTE: If the vee brackets used between the left and right side lines groups on Caterpillar vehicular applications have been previously installed, remove them. Do not reuse these vee brackets. A new clamping arrangement is used on the new 6I0349 and 6I0350 Lines Groups on 3412 Generator Set Industrial, and Marine Engines.
3. Disassemble the tower clamp assembly behind the fuel injection pump. The 9Y3356 Clamp and 9Y3359 Clamp Assembly that form the tower clamp will be reused. (See Section C-C in Illustration 2).
Illustration 2
4. Disconnect all the fuel line nuts at the fuel injection pump and at the adapters in the valve cover bases.
5. Remove the left side and right side fuel lines and clamps as separate assemblies.
NOTE: On DIT Engines, remove the 9Y1112 Bracket Assembly and install a new 6I0348 Bracket Assembly.
6. Remove the plastic caps and plugs and set the new 6I0349 Lines Group (left side) and the 6I0350 Lines Group (right side) in place and hand tighten the fuel line nuts. (See Illustration 1).
NOTE: If any of the ends of the individual fuel lines are not square with the bonnets in the fuel injection pump or the adapters in the valve cover bases, gently bend the lines by hand to align the ends before starting the fuel line nuts. Do not simply force the ends of the lines into place and start the fuel line nuts. This puts unwanted strain on the fuel lines.
7. Position the 9Y3356 Clamp and 9Y3359 Clamp Assembly of the tower clamp assembly around the number 3, 5, and 6 fuel lines and loosely install the original mounting bolt and washer.
8. Using new 9N3388 Screws install a new 9Y3357 Clamp under the upper 9Y3356 Clamp and a new 7C6589 Clamp under the lower 9Y3359 Clamp Assembly. Tighten the screws to 2.25 N ·m (20 lb. in.). (See Section C-C in Illustration 2).
NOTE: Do not overtighten the screws. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screws.
9. Slide a 8T1296 Washer under the plate of the formed damper clamp on the number 4 and 6 fuel lines and loosely install a new OS1590 Mounting Bolt [50.8 mm (2.0 in.)] with a new 9X6458 Washer. (See Section B-B in Illustration 2).
For DIT Engines use a new 0L1351 Bolt [22.2 mm (.87 in.)].
10. Slide two 688438 Spacers under the rear bracket on the left side for the number 7, 9, and 11 fuel lines and loosely install new 0L2070 Mounting Bolts [57.2 mm (2.25 in.)] with new 9X6458 Washers. (See Section D-D in Illustration 2).
For DIT Engines use new 0S1594 Bolts [25.4 mm (1.0 in.)].
11. Slide two 8T1296 Washers under the front bracket on the left side for the number 7, 9, and 11 fuel lines and loosely install new 0S1590 Mounting Bolts [50.8 mm (2.0 in.)] with new 9X6458 Washers. (See Illustration 3).
Illustration 3
For DIT Engines use new 0L1351 Bolts [22.2 mm (.87 in.)].
12. Install new 0S1590 Mounting Bolts [50.8 mm (2.0 in.)] and new 9X6458 Washers for the fuel line brackets on the right side.
For DIT Engines use new 0L1351 Bolts [22.2 mm (.87 in.)].
NOTE: Normally for Steps 9 through 12, the washers and spacers called for under the brackets will correctly fill the gaps between the brackets and the aftercooler housing or the 6I0348 Bracket Assembly. If they are too thick or thin, use the 9X6458 Washers saved from Step 2 and the 8T1296 Washers and 688438 Spacers as needed to fill the gaps. The purpose Of the spacers and washers is to prevent the brackets from putting unwanted strain on the fuel lines.
If there is a gap under the tower clamp assembly, install washers/spacers as needed to fill the gap.
13. Tighten all the bracket mounting bolts.
14. Loosen the fuel line nuts at the adapters in the valve cover bases and use the hand priming pump to purge the air out of the fuel lines. Lightly tighten the fuel line nuts as the air is purged from each line.
15. Tighten all the fuel line nuts to 40 + or - 7 N· m (30 + or - 5 lb. ft.).
16. Wipe up all spilled fuel.
17. Start the engine to purge any remaining air and make sure there are no fuel leaks.
18. Shut-off the engine and tighten the fuel line nuts again to the torque shown above.
19. Paint the fuel lines and clamps around the tower clamp assembly and the formed damper clamp, then touch up all the fuel lines, clamps and brackets as necessary.
Rework Procedure - Group 2
NOTE: If the engine to be reworked is non-aftercooled, clean and pre-paint the new 6I0348 Bracket Assembly in your shop before proceeding to the job site.
Illustration 1
1. Remove the two fuel line brackets from the left side of the aftercooler housing on DITA Engines or at the 9Y1112 Bracket Assembly on DIT Engines. New mounting bolts and washers will be used. Keep the 9X6458 Washers, they may be needed as spacers.
NOTE: The 9Y1112 Bracket Assembly is the large bracket on DIT (non-aftercooled) Engines used to support the fuel line brackets. This bracket is part of the 6N5140 Fastener Group.
2. Remove the complete clamp assembly from the number 4 and 6 fuel lines at the front of the aftercooler housing or the 9Y1112 Bracket Assembly. This bracket is to the right of the tower clamp assembly. A new mounting bolt and washer will be used. Keep the 9X6458 Washer it may be needed as a spacer.
NOTE: On DIT Engines only, remove the mounting bolts for the tower clamp assembly and the fuel line brackets at the right side of the 9Y1112 Bracket Assembly. Carefully remove the 9Y1112 Bracket Assembly and install the new 6I0348 Bracket Assembly. Install the mounting bolts on the tower clamp assembly and the fuel line brackets on the right side. Tighten the mounting bolts.
NOTE: In Steps 3, 6, and 8 do not install the new clamps over paint. Use Emery Paper or a fine sand paper to remove paint on the fuel lines in the area that the new clamps will be installed.
3. Assemble the new 6I4813 Clamp Kit (formed damper clamp) in place of the clamp assembly removed in Step 2. Tighten the screw to 2.25 N ·m (20 lb. in.). (See Section B-B in Illustration 2).
Illustration 2
NOTE: Do not overtighten the screw. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screw.
4. Slide a 8T1296 Washer under the new plate of the new formed damper clamp and loosely install a new 0S1590 Mounting Bolt [50.8 mm (2.0 in.)] with a new 9X6458 Washer. (See Section B-B in Illustration 2).
For DIT Engines use a new 0L1351 Bolt [22.2 mm (.87 in.)].
5. Position the new 4P7144 Bracket in place of left rear fuel line bracket removed in Step 1. Slide two 688438 Spacers under the bracket and loosely install new 0L2070 Mounting Bolts [57.2 mm (2.25 in.)] with new 9X6458 Washers. (See Section D-D in Illustration 2).
For DIT Engines use new 0S1594 Bolts [25.4 mm (1.0 in.)].
6. Assemble the new clamps and screws as shown in Section D-D of Illustration 2. Do not tighten the screws.
7. Position the new 4P7137 Bracket in place of the left front fuel line bracket removed in Step 1. Slide two 8T1296 Washers under the bracket and loosely install new 0S1590 Mounting Bolts [0.8 mm (2.0 in.)] with new 9X6458 Washers. (See Illustration 3).
Illustration 3
For DIT Engines use new 0L1351 Bolts [22.2 mm (.87 in.)].
8. Assemble the new clamps and screws as shown in Illustration 3.
9. Tighten all the screws on both new fuel line brackets to 2.25 N ·m (20 lb. in.).
NOTE: Normally for Steps 4, 5, and 7, the washers and spacers called for under the plate and brackets will correctly fill the gaps between the plate and brackets and the aftercooler housing or the 6I0348 Bracket Assembly. If they are too thick or thin, use the 9X6458 Washers saved from Steps 1 and 2 and the 8T1296 Washers and 688438 Spacers as needed to fill the gaps. The purpose of the spacers and washers is to prevent the plate and brackets from putting unwanted strain on the fuel lines.
10. Tighten the mounting bolts for both brackets on the left side and formed damper clamp next to the tower clamp assembly.
11. Paint the new brackets, clamps and mounting hardware.
Rework Procedure - Group 3
1. Remove the formed damper clamp from the number 4 and 6 fuel lines at the front of the aftercooler housing or the 6I0348 Bracket Assembly. This clamp is to the right of the tower clamp assembly.
Illustration 1
NOTE: The 6I0348 Bracket Assembly is the large bracket on DIT (non-aftercooled) Engines used to support the fuel line brackets. This bracket is part of the 6N5140 Fastener Group.
2. Assemble the new 6I4813 Clamp Kit in place of the early style formed damper clamp removed in Step 1. Tighten the screw to 2.25 N ·m (20 lb. in.). (See Section B-B in Illustration 2).
Illustration 2
NOTE: Do not overtighten the screw. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screw.
3. Make sure that a 8T1296 Washer is under the plate of the new formed damper clamp and install a new 0S1590 Mounting Bolt [50.8 mm (2.0 in.)] with a new 9X6458 Washer. Tighten the mounting bolt. (See Section B-B in Illustration 2).
For DIT Engines use a new 0L1351 Bolt [22.2 mm (.87 in.)].
4. Paint the new parts.
Rework Procedure - Group 4
1. Remove the two 1W9169 Clamps, two 1W9167 Clamp Assemblies, two 9N3388 Screws, two 4B4274 Washers and one 9Y7524 Plate from the number 2 and 8 fuel lines of the new 6I0350 Fuel Lines Group (right side). See the Illustration.
NOTE: If the new 6I0350 Fuel Lines Group has already been painted, remove the paint from the number 2 and 6 fuel lines in the area where the new clamp parts are to be installed.
2. Install the new 1029228 Clamp, 9Y3357 Clamp and the two 5P4939 Screws as shown in the Illustration. The new clamps must be located on the straight portions of the fuel lines. Do not install the clamps on the curved portion of either line. Tighten the screws to a torque o 2.25 N ·m (20 lb.in.).
NOTE: Do not over tighten the screws. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screws.
3. Paint the new clamp and the number 2 and 8 fuel lines where the former clamp was removed.