PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES

Usage:

REBE1705-00

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04Jun2007

O-216

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES
1262 1258 1261 1263		PI31274

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31274" 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 "PI31274" 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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COMPLETION DATE	TERMINATION DATE
31Dec2007	30Jun2008

PROBLEM

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Excess contamination in the fuel is causing accelerated wear on the injectors.

AFFECTED PRODUCT

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Model

Identification Number

C6.6 TIER 3

66600659-00660, 754-764, 766-777, 779-787, 830-834, 836-842, 863-868, 914-918, 987, 989-991, 993-997, 999-1003, 1327, 1396, 1895-1896, 2013-2025, 2109, 2112-2113, 2128-2134, 2151-2164, 2356-2360, 2374-2387, 2413, 2415-2420, 2449-2450, 2492-2493, 2498-2499, 2501-2505, 2511-2514, 2653-2661, 2700-2703, 2705, 2710-2715, 2718-2723, 2826-2827, 2829-2834, 2836-2842, 2887-2896, 2898, 2900-2907, 2909-2919, 2933-2935, 2937-2939, 2975, 2977-2982, 3017-3019, 3052-3058, 3068-3073, 3078, 3134

PARTS NEEDED

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Qty	Part Number	Description
1	3096653	FILTER AS-FUEL

ACTION REQUIRED

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Installation of an improved fuel filter arrangement.

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OWNER NOTIFICATION

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An example of an Owner Notification Letter is attached.

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 2.5-hour job
NOTE: The breakdown for the 2.5 Hour job, is as follows: 1.5 hours will be allowed for a diagnostic leak off check and 1.0 hour will be allowed for the installation of the improved fuel filter arrangement. NOTE: Average results of the three leak-off measurement readings >50ml/30 seconds indicates a future injector failure could occur. A high leakoff test should initiate a replacement of the fuel system components. If the outcome of the leak-off test indicates that a future injector failure could occur, it is perfectly acceptable to apply the improved filter arrangement only, return the machine into service, and schedule the additional components at a later date. The time and cost for replacement of the additional components for the fuel system should be submitted to Caterpillar as a separate warranty claim from the improved filter arrangement. Use the injector part number as the part causing failure.

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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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Example of Owner Notification Letter

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING AN IMPROVED FUEL FILTER ARRANGEMENT

MODELS INVOLVED - CERTAIN C6.6 LOOSE ENGINES

Dear Caterpillar Product Owner:

The filtration system prior to the introduction of this service letter could allow particles to get through and damage the injectors causing high leak off and the inability to start. The new improved filtration system will prevent this from happening and increase the protection of the injectors.

If your engine is in the list of engines affected by this service letter, 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 04Jun2007 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 04Jun2007 Service Letter

Rework Procedure

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ELECTRONIC UNIT INJECTOR LEAK OFF TEST.

Ensure the fuel system components (and the surrounding area) are cleaned externally and free from debris prior to breaking into the fuel system ? see the section ?Engine Clean? in the OMM.

Ensure that the engine is shut down. Locate the fuel leak off
connector (1) on the cylinder head.

Image1.1.1

Remove the leak off pipe (2) from the connection on the cylinder head (1). Use a clean rubber hose, two hose clamps, and a suitable bolt to make a sealed cap (3) for the end of the fuel leak off pipe (2). Insert a bolt (4) into the end of the rubber hose (6). Secure the bolt to the rubber hose with a hose clamp (5). Place the rubber hose assembly (3) onto the end of the fuel leak off pipe (2) and tighten the hose clamp (7).

Image1.2.1

Push a clean length of plastic hose (8) onto the leak off connector (1) on the cylinder head. Place the opposite end of the plastic hose (8) into a clean, graduated fuel container (9).

Image1.3.1

Disconnect the three wiring harness connectors (10) on the top
cover in order to prevent the engine from starting.

Image1.4.1

Crank the engine with the starter motor for 30 seconds.

Record the amount of fuel from the leak off connector on the cylinder head that has been collected in the container.

Repeat test a total of 3 times.

If the average fuel volume for the 3 leak off measurement readings is >50ml/30 seconds then the following fuel system components will also be required to be changed:

6 x Injectors
6 x High-pressure pipes from fuel rail to injector
6 x Injector clamp bolt(278-5170)
6 x Top cover sleeve(277-5067)

NOTE: These additional components may be changed at a later scheduled date. See note in Service Claims Allowances.

If the average fuel volume for the 3 leak off measurement readings is <50ml/30 seconds then no additional fuel system components are required and only the installation of the improved fuel filter assembly, outlined in this PI, need be applied.

The leak off pipe (1) should be re-connected to the cylinder head and the three wiring harness plugs (10) should be re-connected.

Important Notes:

Common rail fuel technology requires a high degree of cleanliness. It is therefore imperative to adhere to all cleanliness requirements within this rework procedure. For example, re-using dirty caps will have a detrimental effect on product durability.

Parts must be inspected prior to use to ensure capping is intact and parts are clean and undamaged.

All new components should remain bagged and capped until immediately before use.

Any fuel system component that is removed or exposed should be capped with new, clean caps to prevent dirt ingress, e.g. male connector when low pressure pipe is removed. Use parts contained in anti contamination kit No. 278-4138.

Before attempting any work on the fuel system ensure that the engine is cleaned of any dirt that might contaminate the fuel system.

Clean up any spilt fuel before undertaking further work.
Check there is adequate clearance around all low pressure pipes, and that any clamping is in place and correctly orientated.

NO attempt should be made to clean / flush filter elements for re-use.

DO NOT PRE-FILL THE FILTERS.

Fuel can be hot after running. Care must be taken to ensure hot fuel does not come in contact with exposed skin. Allow engine to cool before undertaking any work.

1 SYSTEM DIAGRAM OF LOW PRESSURE FUEL SYSTEM.

Image1.5.1

NOTE: Primary Filter may be mounted off engine.

2 SYSTEM FITTING

The field re-fit kit contains one secondary fuel filter assembly.

2.1 Removal of existing components

The secondary fuel filter assembly should be removed by disconnecting the 3 quick connectors indicated in Image 1.6.1. Depress the release button and pull pipe off the spigot. Immediately plug the pipe with a new clean plug from anti contamination kit. Unbolt and remove the filter assembly, pipe support bracket, and P-Clip.

Image1.6.1

All other low pressure fuel system components must be left on the engine.

2.2 Bracket Preparation

Image1.7.1

Remove paint around the paint shadow left by the original filter head, this is to ensure metal-to-metal contact all around the filter head.

2.3 Filter assembly.

Image1.8.1

Assemble secondary fuel filter, support bracket, and P-clip onto mounting bracket by re-using 2 M10 flange head bolts tightened to 28 +/- 7Nm. Ensure all filter ports remain plugged at all times until the pipes are ready to be fitted. Remove plugs and reconnect pipes to original positions as shown in Image 1.6.1. R efit the P-clip to support the fuel line.

Prime the fuel system as directed in the Systems Operation Test & Adjust section ? Fuel System Prime.

Run the engine and check for fuel leakage, rectify leaks as necessary.