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:

REBE1973-01

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27Sep2007

(Revised 02Nov2007)

O-426

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES
1262 1258 1261 1263		PI31360

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31360" 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 "PI31360" 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 27Sep2007 Service Letter. Changes have been made to the Parts Required.

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COMPLETION DATE	TERMINATION DATE
31Mar2008	30Sep2008

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	66600239, 356, 514, 1430, 1434, 1522-1525, 2620-2625, 2629-2639, 2725-2730, 2764-2766, 2768-2770, 2773-2774, 2782, 2784-2799, 2983, 2985-2989, 3235-3236, 3280, 3340

PARTS NEEDED

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Qty	Part Number	Description
4	1P4278	CLAMP-HOSE
4	2159513	CONNECTOR-SPL
4	2159515	CONNECTOR-SPL
1	2776165	CONNECTION-FUEL
1	3087480	FILTER AS-FUEL
1	3111110	FILTER AS-FUEL
1	3111175	TUBE-LEAK OFF
1	3111666	BRACKET
1	3111684	TUBE

ACTION REQUIRED

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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%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.5-hour job
Note: the breakdown of the 2.0 hour job, is as follows: 1.0 hour 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:If the average results of the three leak off measurement readings are >50ml / 30 seconds, this indicates that a future injector failure exists. A high leak off test result should initiate the replacement of the fuel system components. If the outcome of the leak off test indicates that a future injector failure exists,it is perfectly acceptable to apply the improved filter arrangement only and return the machine into service and schedule the fitting of 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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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 FUEL FILTER ARRANGEMENT ON CERTAIN C6.6 ENGINES

MODELS INVOLVED - CERTAIN C6.6 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 inability to start. The new improved filtration system will prevent this from happening and increase the protection of the injectors. The fuel filter arrangement needs to be replaced on the products listed below.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. You will not be charged for this service.

Please refer the dealer to their Service Letter dated 27Sep2007 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 27Sep2007 Service Letter

Rework Procedure

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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 instruction, 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 anti contamination kit part 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 clamps are 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.

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 that has been collected from the leak off connector on the cylinder head which is now in the container.

Repeat the test a total of 3 times.

If the average fuel volume for the 3 leak off measurement readings are >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)

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

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

SYSTEM DIAGRAM OF LOW PRESSURE FUEL SYSTEM.

Image1.5.1

SYSTEM FITTING

The field re-fit kit contains:

2 X Secondary 4m fuel filter assembly.
Fuel filter bracket.
Nylon and steel fuel pipe (Leak off / Fuel return).
Steel fuel pipe (Secondary fuel filter to HP fuel pump inlet).
2 X Flexible fuel hose (Supplied by OEM)
1 X 277-6165 connector.

The below notes describe the fitting process required for fitting the rework kit (this assumes the machine is already fitted with an existing two filter Low Pressure fuel system with V0201 configuration).

Removal Of Existing Components:

Remove low pressure fuel pipes: A, B, and C Steel or plastic pipe. Remove pipe-to-pipe clamps indicated in Image 1.6.1. For Pipe A, B, and C quick connectors, depress the release button and pull pipe off the spigot. Immediately cap the spigot with a new clean cap. For steel version of pipe C with compression fittings, completely undo the nut nearest the spigot and remove the pipe assembly. Immediately cap the pump spigot with a new clean cap. Leave nut and olives in place.

Image1.6.1

Undo and remove bolts to remove filter assembly and bracket indicated in Image 1.7.1

Image1.7.1

Fitting of the new Fuel Filter Bracket

Image1.8.1

Assemble fuel filter bracket Pt. No. 311-1666 onto induction cover (see Image 1.8.1) use 2 M8 flange head bolts Pt. No. 6I-0260 tighten to a torque of 22 Nm +/- 5.5 Nm.

NOTE: Ensure filter assembly has hole as shown in Image 1.9.1. The ID mark identifies the filter head has a long spigot to seal against the O-ring of the new filter.

New filter assembly:

Image1.9.1

Image1.9.2

Assemble fuel filter assembly 308-7480 onto filter bracket (see Image 1.9.2) use 2 M10 flange head bolts 6I-0593 tighten to a torque of 55 Nm +/- 10 Nm.

Leak Off Pipe Assembly:

Assemble leak off pipe, 311-1175 in the position shown in Image 1.10.1. Connect quick connector to fuel pump leak off spigot A, Connect quick connector to filter bleed spigot B, Assemble steel injector leak off pipe C,using fitting 277-6165.
Put the nut then the olive onto the pipe end, push the pipe fully into the fitting and tighten by hand.
If the original fitting in the fuel rail is damaged - then replace it, otherwise just use the nut and olive from the new connector.
Press pipe into the pipe clamps indicated.

Image1.10.1

Steel Pipe Assembly:

Care must be taken to ensure part cleanliness, assemble immediately after removing protective caps.

Assemble steel pipe, 311-1684 in the position shown in Image 1.11.1, locate both compression fittings as far as possible onto filter outlet and pump inlet spigots. Tighten the nuts (four places in total, two on each compression fitting) tighten to
26 Nm +/- 4Nm for steel fittings or 21 Nm +/- 4 Nm for brass fittings (Equivalent to 1 and 1/4 turns).

NOTE: Where a compression fitting has already been assembled to a spigot, the assembly procedure is modified, tighten the nut until a sharp rise in torque is felt, then tighten an additional 1/6 to 1/3 turns to seal. A special tool such as a bent wrench will be required to tighten the lower compression fitting, as access is limited. Adhere to cleanliness guidelines at all times.

Image1.11.1

Remote mounted filter:

Assemble remote mounted filter 311-1110 on machine chassis. Connect flexible fuel hose between A-B and C-D. Use ISO quick fit spigots supplied or remove and use a suitable alternative. Connection E must not be modified.

Make a flexible hose from a suitable hose to specification SAE J30R9, (4) 1P-4278 clamps and a selection of connectors as required from part numbers 215-9515 (90 degree) and 215-9513 (straight connector). The required internal diameter needs to be 8.00mm. (Refer to Image 1.13.1)

Image1.12.1

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 as appropriate.