PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN IMPROVED CLAMPING SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN C6.6 IOPU/GENSET APPLICATIONS Caterpillar


PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN IMPROVED CLAMPING SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN C6.6 IOPU/GENSET APPLICATIONS

Usage:

REBE1452-00

19Jan2007


U-27
O-27

 
Priority
  
  

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN IMPROVED CLAMPING SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN C6.6 IOPU/GENSET APPLICATIONS

1252
PI31217
NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31217" 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 "PI31217" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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.


COMPLETION DATE

TERMINATION DATE

31Jul2007 31Jan2008

PROBLEM

The high-pressure fuel line (290-3910) fitted between the fuel pump and the fuel manifold can see high vibration under certain conditions. This vibration could possibly result in fuel line failure.

AFFECTED PRODUCT

Model Identification Number
C6.6 Tier 3  66600651-00653, 657-658, 662-663, 711, 919, 946, 950, 952, 955, 958-960, 1005-1019, 1047-1052, 1069-1075, 1090-1100, 1102, 1107, 1157-1159, 1161, 1165, 1170, 1178, 1200-1211, 1226-1242, 1244, 1264, 1329-1330, 1349-1351

PARTS NEEDED

Qty

Part Number Description
1 2388028 CABLE-TIES
4 2414291 SCREW
1 2784138 PLUG KIT
4 2801889 CLAMP
4 2801890 CLAMP
4 2801891 ISOLATOR
1 2903910 TUBE FUEL-INJ
1 3002940 BRACKET
1 3002944 STUD
4 6I0254 BOLT
1 6I4374 BOLT

ACTION REQUIRED

Please refer to the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
100%
100%
0%
0%
0%
0%

 NOTE: This is a 1.0-hour job


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.
 
 
 
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN IMPROVED CLAMPING SUPPORT FOR THE FUEL DELIVERY LINE

MODELS INVOLVED - CERTAIN C6.6 IOPU/GENSET APPLICATIONS

Dear Caterpillar Product Owner:
The high-pressure fuel line (290-3910) fitted between the fuel pump and the fuel manifold can see high vibration under certain conditions. This vibration could possibly result in fuel line failure.

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 19Jan2007 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 19Jan2007 Service Letter


Rework Procedure


 
This is a two-stage rework procedure. Stage 1 replaces the fuel pipe between the fuel pump and fuel manifold. Stage 2 adds a bracket and clamp for the fuel pipe.

Stage 1 of rework

Assembly instructions for fitting new fuel pipe (pump to fuel manifold) (Items 1 through to 13)

1.Thoroughly clean the area around the pipe to be removed (290-
3910)

2.Remove existing pipe and pipe clamps

3.Fit new clean caps (Plug Kit 278-4138) to the exposed fuel pump and fuel manifold connections if the new pipe is not going to be assembled immediately.

4.Check that the HP pipe is free from faults and both ends of the pipe have the protective caps fitted. Do not remove the caps until the point at which the pipe is fitted.

5. Fit three rubber isolators (280-1891) onto the pipe.

6.Assemble clamps around rubber isolators (280-1890 back, nearest cylinder head 280-1889 front) onto the pipe with M5 cap screws (241-4291) finger tight.

7.Remove protective caps from the pipe ends, fuel pump outlet and fuel manifold inlet. Fit the pipe, loosely tightening the nuts at both ends, and ensuring the pipe ends are fully engaged in the conical seats.

8.Fit M8 bolts (6I0254), loosely tightening them through the clamps and into the cylinder head.

9.Tighten the nuts at both ends of the pipe to a torque of 30Nm ? 2.4Nm. (22 ? 1.5 lbf ft)

10.Ensure torque is applied perpendicular to the thread.

11.Tighten the M8 bolts into the cylinder head to a torque of 22Nm ? 5.5Nm. (16 ? 4 lbf ft)

12.Tighten the M5 cap screw to a torque of 10Nm ? 1.0Nm. .( 7 ? 0.7 lbf ft)

13.Pipe must not touch any other component over its length except where clipped (see fig 1.1.1).
Image1.1.1
 
Stage 2 of rework

Assembly instructions for additional HP pipe clamp and bracket (Items 14 through to 23)

14.Remove centre manifold bolt (6I4793) and washer and existing M8 stud/cover fixing (293-9902). Discard

15.Assemble bracket (300-2940) to manifold

16.Fit a new M8 x 60LG bolt (6I4374) in centre hole, to hold bracket in position. Fit new M8 stud/cover fixing (300-2944) to front hole. Do not tighten, do not fit washer under head of bolt.

17.Assemble heavy duty clamp rubber and clamps(part numbers 280-1891, 280-1890, 280-1889, 241-4291)to HP pipe as instructions 5 and 6 above. See figure 1.2.1 for orientation.
18.Slide clamp into place, aligning slotted hole with threaded hole in bracket. Finger tighten M5 cap screw, holding clamp in place.

19.Assemble M8 x 30LG (6I0254) bolt holding clamp to bracket. The position of the bracket on the manifold may have to be adjusted to make this easier. Align the clamp with the bracket.
N.B. Do not apply excessive pressure to the pipe.

20.Tighten M8 x 60LG bolt, and M8 stud down to manifold to a torque of 22Nm ?5.5Nm. (16 ? 4 lbf ft)

21.Tighten M8 x 30LG bolt fastening clamp to bracket to a torque of 22Nm ?5.5Nm. (16 ? 4 lbf ft)

22.Torque M5 cap screw to 10Nm ? 1.0Nm. ( 7 ? 0.7 lbf ft)

23.Finally cable tie the wiring loom tightly to the bracket to prevent chafing, figure 1.2.1 for position and orientation.
Image1.2.1
 
 

Caterpillar Information System:

PRODUCT IMPROVEMENT PROGRAM FOR REMOVING ALL 208-8464 & 208-9636 FAN GUARDS FROM DEALER PART STOCK. PRODUCT IMPROVEMENT PROGRAM FOR REMOVING ALL 208-8464 & 208-9636 FAN GUARDS FROM DEALER PART STOCK.
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN GUARD ON CERTAIN 3456 GENERATOR SETS(60HZ) PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FAN GUARD ON CERTAIN 3456 GENERATOR SETS(60HZ)
PRODUCT SUPPORT PROGRAM FOR REMOVING SPACER FROM THE AUTOMATIC TIMING ADVANCE ON CERTAIN 3412C GENERATOR SETS PRODUCT SUPPORT PROGRAM FOR REMOVING SPACER FROM THE AUTOMATIC TIMING ADVANCE ON CERTAIN 3412C GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR INTAKE VALVE LOW PRESSURE ACTUATORS REPLACEMENT ON CERTAIN C13 TRUCK ENGINES. PRODUCT SUPPORT PROGRAM FOR INTAKE VALVE LOW PRESSURE ACTUATORS REPLACEMENT ON CERTAIN C13 TRUCK ENGINES.
PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE GENERATOR ADAPTER BOLTS ON CERTAIN C9, C15, 3406, AND 3456 GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE GENERATOR ADAPTER BOLTS ON CERTAIN C9, C15, 3406, AND 3456 GENERATOR SETS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER BOOST AIR PIPES ON CERTAIN 3512B HD LOCOMOTIVE ENGINES. PRODUCT SUPPORT PROGRAM FOR REPLACING THE TURBOCHARGER BOOST AIR PIPES ON CERTAIN 3512B HD LOCOMOTIVE ENGINES.
PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTURATORS FOR THE INTAKE VALVE ON CERTAIN C13 TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF THE LOW PRESSURE ACTURATORS FOR THE INTAKE VALVE ON CERTAIN C13 TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A 296-8050 HIGH INERTIA COUPLING GROUP ON CERTAIN G3520C GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A 296-8050 HIGH INERTIA COUPLING GROUP ON CERTAIN G3520C GENERATOR SETS
Product Improvement Program to inspect/repair fan drive bearing on certain C32 fan drives. Product Improvement Program to inspect/repair fan drive bearing on certain C32 fan drives.
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 247-0308 GENERATOR SET COUPLING ON CERTAIN G3520C GENERATOR SETS WHEN THE MAXIMUM AMBIENT TEMPERATURE NEAR THE DAMPER GROUP IS LESS THAN 50C. PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 247-0308 GENERATOR SET COUPLING ON CERTAIN G3520C GENERATOR SETS WHEN THE MAXIMUM AMBIENT TEMPERATURE NEAR THE DAMPER GROUP IS LESS THAN 50C.
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR SET COUPLING 5N-3765 WITH A 296-8050 ON CERTAIN G3520C GENERATOR SETS WHEN THE MAXIMUM AMBIENT TEMPERATURE NEAR THE DAMPER GROUP IS LESS THAN 50C. PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE GENERATOR SET COUPLING 5N-3765 WITH A 296-8050 ON CERTAIN G3520C GENERATOR SETS WHEN THE MAXIMUM AMBIENT TEMPERATURE NEAR THE DAMPER GROUP IS LESS THAN 50C.
PRODUCT SUPPORT PROGRAM FOR FITTING A MODIFIED FUEL FILTER ARRANGEMENT TO CERTAIN C6.6 ENGINES USED IN TAMROCK ROCKDRILL APPLICATIONS PRODUCT SUPPORT PROGRAM FOR FITTING A MODIFIED FUEL FILTER ARRANGEMENT TO CERTAIN C6.6 ENGINES USED IN TAMROCK ROCKDRILL APPLICATIONS
PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE FAN DRIVE PULLEY ON CERTAIN C15 GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE FAN DRIVE PULLEY ON CERTAIN C15 GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE FAN DRIVE PULLEY ON CERTAIN C15 GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM TO REPLACE THE FAN DRIVE PULLEY ON CERTAIN C15 GENERATOR SETS
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 110-4422 AND 110-4424 RECTIFIERS, 4P-6009 VARISTORS, AND ASSOCIATED HEAT SINK ASSEMBLIES FROM DEALER INVENTORY PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 110-4422 AND 110-4424 RECTIFIERS, 4P-6009 VARISTORS, AND ASSOCIATED HEAT SINK ASSEMBLIES FROM DEALER INVENTORY
PRODUCT SUPPORT PROGRAM FOR REPLACING 266-0053 AFTERCOOLERS ON 3406E ENGINES OWNED BY NEW YORK WATERWAY. PRODUCT SUPPORT PROGRAM FOR REPLACING 266-0053 AFTERCOOLERS ON 3406E ENGINES OWNED BY NEW YORK WATERWAY.
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 0R9661, 0R8209, 10R1491, and 0R9680 SHORT BLOCKS FROM DEALER PART STOCK. PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 0R9661, 0R8209, 10R1491, and 0R9680 SHORT BLOCKS FROM DEALER PART STOCK.
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 10R4134 SHORT BLOCKS, 10R4139 SHORT BLOCKS, 10R4144 LONG BLOCKS, and 10R4145 LONG BLOCKS FROM DEALER PART STOCK. PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 10R4134 SHORT BLOCKS, 10R4139 SHORT BLOCKS, 10R4144 LONG BLOCKS, and 10R4145 LONG BLOCKS FROM DEALER PART STOCK.
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 3408 AND 3412 REMANUFACTURED ENGINES FROM DEALER PART STOCK. PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 3408 AND 3412 REMANUFACTURED ENGINES FROM DEALER PART STOCK.
PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF INTAKE VALVE LOW PRESSURE ACTUATORS ON CERTAIN C13 TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR THE REPLACEMENT OF INTAKE VALVE LOW PRESSURE ACTUATORS ON CERTAIN C13 TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN MACHINES AND INDUSTRIAL APPLICATIONS POWERED BY C6.6 ENGINES PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING ADDITIONAL SUPPORT FOR THE FUEL DELIVERY LINE ON CERTAIN MACHINES AND INDUSTRIAL APPLICATIONS POWERED BY C6.6 ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING PUSH RODS IN CERTAIN 3126B COMMERCIAL ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING PUSH RODS IN CERTAIN 3126B COMMERCIAL ENGINES
PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT ENGINE ACCESSORY DEVICE ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES PRODUCT SUPPORT PROGRAM FOR REWORKING THE FRONT ENGINE ACCESSORY DEVICE ON CERTAIN C13 ON-HIGHWAY TRUCK ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE AUXILIARY CIRICUIT HEATER OPTIONS ON CERTAIN C9, C15 AND C18 GENERATOR SETS PRODUCT IMPROVEMENT PROGRAM FOR REWIRING THE AUXILIARY CIRICUIT HEATER OPTIONS ON CERTAIN C9, C15 AND C18 GENERATOR SETS
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.