PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOW PRESSURE FUEL RETURN HOSES ON CERTAIN C27 AND C32 EPG ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOW PRESSURE FUEL RETURN HOSES ON CERTAIN C27 AND C32 EPG ENGINES

Usage:

REBE2371-01

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27Aug2007

(Revised 10Mar2008)

U-417

A-343

D-343

O-368

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE LOW PRESSURE FUEL RETURN HOSES ON CERTAIN C27 AND C32 EPG ENGINES
1274		PI31334

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31334" 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 "PI31334" 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 27Aug2007 Service Letter. Changes have been made to Affected Product.

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COMPLETION DATE	TERMINATION DATE
29Feb2008	31Aug2008

PROBLEM

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The low pressure fuel hoses need to be replaced on certain C27 and C32 EPG engines. The existing fuel hoses may fail due to pressure spikes.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C27	DWB00108-00264, 266-279, 281-359, 362-424, 426-427, 430-431, 433-493, 495-536, 538-542, 544-547, 552-556, 563-568, 570-576, 578-583, 585, 587-589, 591-593, 595-597
C32	SXC00632-00923, 925-987, 989-1038, 1040-1054, 1059-1103, 1105-1115, 1117-1216, 1219-1239, 1241-1278, 1281-1332, 1334-1335, 1337-1383, 1388-1392, 1395-1457, 1459-1461, 1463-1466, 1469-1486, 1489-1599, 1601-1608, 1611-1622, 1625-1627, 1630-1641, 1643-1691, 1699-1712, 1714-1717, 1721-1772, 1774-1788, 1790-1794, 1796-1802, 1804-1820, 1822-1823, 1825-1833, 1835, 1838, 1843-1844, 1850, 1852-1853, 1855-1859, 2052-2053, 2076, 2091

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*****Group 2*****
PMC32	MED00100-00161, 163

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	0S0509	BOLT
2	0S1571	BOLT
2	3B1915	BOLT
1	5M2894	WASHER-HARD
2	6B0933	SPACER
2	7V6571	GROMMET
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
2	9X6458	WASHER-HARD
1	3171378	HOSE AS
1	3171379	HOSE AS
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.
*****Group 2*****
2	0S1571	BOLT
2	3B1915	BOLT
2	6B0933	SPACER
2	7V6571	GROMMET
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
2	9X6458	WASHER-HARD
1	3171378	HOSE AS
1	3171379	HOSE AS
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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Replace current low pressure fuel hoses and miscellaneous hardware. Refer to the attached Rework Procedure.

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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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.0-hour job for Group 2

PARTS DISPOSITION

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 REPLACING THE LOW PRESSURE FUEL RETURN HOSES ON CERTAIN C27 AND C32 EPG ENGINES

MODELS INVOLVED - Certain C27 and C32 EPG engines

Dear Caterpillar Product Owner:

The return fuel hoses need to be replaced on the products listed below. The existing fuel hoses may fail. 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 27Aug2007 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 27Aug2007 Service Letter

Rework Procedure

Group Number 1

Step 1. Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated.

Step 2. Locate strap (item 1), cut and remove to relocate wiring harness. Remove intake manifold bolt that secures the 4P-8134 ladder clip, remove the ladder clip, and replace and re-tighten the intake manifold bolt to proper torque specification. Retain 4P-8134 ladder clip for next step. (Image 1.2.1)

Image1.2.1

Step 3. Install 4P-8134 ladder clip (item 2) with 0S-0509 bolt (item 3) and 5M-2894 washer (item 4) on second landing of the rear support casting (item 5). Secure wiring harness with a tie strap. (Image 1.3.1)

Image1.3.1

Step 4. Disconnect the hose from the head (items 6 & 7) on both sides of the engine, and allow fuel to drain from the hose into an appropriate container. (Images 1.4.1 and 1.4.2)

Image1.4.1

Image1.4.2

Step 5. Loosen the fittings (items 8 & 9) at the 237-4895 manifold and remove P-clips from both sides (item 10) of the engine to remove old hoses. Stud (item 11) needs to be removed on both sides of engine to allow space for new grommet clip. (Images 1.5.1 and 1.5.2)

Image1.5.1

Image1.5.2

Step 6. Install 3B-1915 bolt and original washer into upper hole (item 12). Install 317-1378 hose finger tight on left side of engine at the manifold and head. Final torque should be applied using two wrenches to prevent hose from twisting. Place the 7V-6571 grommet on the hose and position near the lower hole (item 13) in the rear housing support. Install the 8T-1889 and 8T-1890 2-piece clip over the 7V-6571 grommet as shown. Insert 0S-1571 bolt through 9X-6458 washer, the 2 piece clips, the 6B-0933 spacer, the rear housing support, and thread into the rear housing. Repeat process on right side using 317-1379 hose. (Image 1.6.1)

Image1.6.1

Step 7. Make any adjustments necessary to the length of hose above or below the grommet and the angle of two-piece clip.

Step 8. Ensure adequate clearance between the hose and all other parts on the engine.

Step 9. Hose orientation should look similar to hoses shown in Images 1.9.1 and 1.9.2.

Image1.9.1

Image1.9.2

Step 10. Once all final adjustments are made, tighten all fasteners and fittings to production torque specifications. Inspect the hoses again to ensure clearance and make any adjustments necessary.

Group Number 2

Follow these steps to complete Service Letter for Power Module Group 2 Engines.

Step 1. Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated.

Step 2. Remove the upper stud bolts and P clips from the rear housing support on both sides of the engine (item 1). Remove the lower bolts on the rear housing support on both sides of the engine (item 2). Disconnect the hose from the head on both sides of the engine (item 3), and allow fuel to drain from the hose into an appropriate container. (Image 2.3.1)

Image2.3.1

Step 3. Disconnect the hoses (items 4 and 5) from the 237-4895 manifold and remove hoses. (Image 2.4.1)

Image2.4.1

Step 4. Install 3B-1915 bolt and original washer into upper hole (item 6) on the rear housing support. Route 317-1378 hose on the left side of the engine under the wiring harness and connect to the 237-4895 manifold. Connections should only be made finger tight. Final torque should be applied using two wrenches to prevent hose from twisting. Place the 7V-6571 grommet on the hose and position near the lower hole (item 7) in the rear housing support. Install the 8T-1889 and 8T-1890 2-piece clip over the 7V-6571 grommet as shown below. Insert 0S-1571 bolt through 9X-6458 washer, the 2 piece clips, the 6B-0933 spacer, the rear housing support, and thread into the rear housing. Repeat process on ride side of engine using the 317-1379 hose. (Images 2.5.1 and 2.5.1)

Image2.5.1

Image2.5.2

Step 5. Make any adjustments necessary to the length of hose above or below the grommet and the angle of two-piece clip.

Step 6. Ensure adequate clearance between the hose and all other parts on the engine.

Step 7. Hose orientation should look similar to hoses shown in Images 2.8.1 and 2.8.2.

Image2.8.1

Image2.8.2

Step 8. Once all final adjustments are made, tighten all fasteners and fittings to production torque specifications. Inspect the hoses again to ensure clearance and make any adjustments necessary.