Product Support Program For Installing New Fuel Injection Line Groups On Certain D10N Tractors; 651E And 657E Tractors; 772B Tractors; 773B Trucks; And 992C Loaders Caterpillar

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 "PS4708" 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: This Revised Service Letter replaces the May 11, 1992 (Revised July 1992) Service Letter. Group 3 Affected Product have been added as well as additional identification numbers. Changes have been made to the Group 1 and Group 2 Parts Needed. Illustrations 3 and 4 were added.

NOTE: Any Group 1 or Group 2 Affected Product previously reworked under this Program needs to be reworked again as Group 3 Affected Product to include all of the latest changes.

Termination Date

Problem

The fuel lines on certain D10N Tractors; 651E And 657E Tractors; 772B Tractors; 773B Trucks; and 992C Loaders may fail. New fuel line groups can be installed that have a longer service life.

Affected Product
Model & Identification Number

Group 1

D10N (2YD442-1937, 2YD1939, 2YD1942)

651E (89Z170-172, 89Z174-187, 89Z189-270)

657E (90Z183-206; 91Z310-434)

772B (64W178-183)

773B (63W2172, 63W2173, 63W2175, 63W2177-3417, 63W3419; 5SC1-140)

992C (49Z1120-1878)

Group 2

D10N (2YD1938, 2YD1940-1941, 2YD1943-2230)

657E (90Z207-208; 91Z435-460)

772B (64W184-208)

773B (63W3418, 63W3420-3686)

992C (49Z1879-2015)

Group 3

D10N (2YD2231-2406)

657E (90Z209-220)

773B (63W3687-3940)

992C (49Z2016-2125)

Parts Needed

Group 1

1 - 7C6589 Clamp

2 - 7C6591 Clamp

2 - 7C7747 Clamp

1 - 7E3539 Lines Group

1 - 6I0347 Bracket Assembly

1 - 6I0361 Lines Group

6 - 9N3388 Screw-Lock

2 - 4P3677 Clamp

2 - 4P3678 Clamp

8 - 5P4939 Screw A

2 - 0L2070 Bolt

5 - 0S1590 Bolt

3 - 8T1296 Washer

2 - 9Y3357 Clamp

2 - 688438 Spacer

1 - 1029228 Clamp Assembly

Group 2

1 - 6I0347 Bracket

2 - 7C6591 Clamp

2 - 7C7747 Clamp

2 - 4B4274 Washer

2 - 9N3388 Screw

1 - 6I4813 Clamp Kit

1 - 8T1296 Washer

2 - 5P4939 Screw

1 - 9Y3357 Clamp

1 - 1029228 Clamp Assembly

Group 3

2 - 5P4939 Screw

1 - 9Y3357 Clamp

1 - 1029228 Clamp Assembly

Action Required

See the attached procedure.

Service Claim Allowances

Group 1 Affected Product

All Group 2 Affected Product

NOTE: This is a 1-hour job.

All Group 3 Affected Product

NOTE: This is a .3-hour job. Submit a supplemental claim for Group 3 if a claim for Group 1 or 2 has already been submitted.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach. (1-Rework Procedure)

Rework Procedure

Refer to the following instructions and illustrations. Replace the existing fuel lines and their related parts with the new fuel line groups.

NOTE: To insure correct clamp locations, install left and right fuel line groups as assembled. However, if clamps are removed, mark locations to insure correct positions when reassembling.

NOTE: On the 992C Wheel Loader, it is necessary to remove the 6N8322 Air Outlet Tube Assembly to be able to install the right bank fuel line group.

NOTE: Tighten the fuel line clamp screws to a torque of 2.25 N· m (20 lb in). Do not over tighten. Use a 6V6069 Torque Screwdriver or similar tool to tighten the screws.

Group 1 Procedure

1. Clean and paint the new 6I0361 and 7E3539 Fuel Line Groups before proceeding to the job site.

A) "Tape Off" the number 3, 5, and 6 fuel lines in the area of the tower clamp. (See Illustration 1 - Part 4 of 5, Section C-C)

B) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the fuel lines.

C) Clean and paint the fuel line groups.

D) 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. Transport the fuel line groups in their original boxes.

2. Remove all mounting bolts from the fuel line brackets at the aftercooler housing. Except for the tower clamp assembly, new mounting bolts and washers will be used. Keep the washers. The washers may be needed later as spacers.

3.

A) Disassemble the tower clamp assembly behind the fuel injection pump. The 9Y3356 Clamp and 9Y3359 Clamp As. that form the tower clamp will be reused. (See Illustration 1 - Part 4 of 5, Section C-C)

B) Disconnect the 2 line clamps from the 9Y3361 Bracket (Front V Bracket).

C) Disconnect the 6 line clamps from the 7E5779 Bracket (Large V Bracket).

4. Disconnect all the fuel lines at the fuel injection pump and at the adaptors in the valve cover bases.

5.

A) Remove the left and right side fuel line groups as separate assemblies.

B) Remove the 9Y3361 Bracket (Front V Bracket). Replace it with a new 6I0347 Bracket.

6. Remove the plastic caps and plugs from the fuel lines. Set the new 6I0361 Fuel Lines Group (left side) and the new 7E3539 Fuel Lines Group (right side) in place and hand tighten the fuel nuts. (See Illustration 1 - Part 1 of 5).

NOTE: If any of the ends of the individual fuel lines are not square with the bonnets in the fuel injection pump or with the adaptors 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 number 3, 5, and 6 fuel lines. Loosely install the original mounting bolt and washer.

8.

A) Using new 9N3388 Screws, install a new 9Y3357 Clamp under the upper 9Y3356 Clamp and a new 7C6589 Clamp under the lower 9Y3356 Clamp Assembly. Tighten the screws to a torque of 2.25 N ·m (20 lb. in.) (See Illustration 1 - Part 4 of 5, Section C-C).

NOTE: Do not overtighen the screws. Use a 6V6069 Torque Screwdriver or similar tool to tighten screws.

B) Attach the fuel line groups to the 6I0347 Bracket (Front V Bracket) using (2) new 9N3388 Screws, (2) 4B4274 Washers, and (2) 7C6591/7C7747 Clamps.

C) Attach the fuel line groups to the 7E5779 Bracket (Large V Bracket) with new (6) 7M9831 Screws, (6) 4B4274 Washers, and (2) 4P3677/4P3678 Clamps. If the engine does not have a 7E5779 Bracket, install one.

9. Slide an 8T1296 Washer under the plate of the formed damper clamp on the number 4 and 6 fuel lines. Install a new 0S1590 Bolt [50.8 mm (2.0 in.)] with a new 9X6458 Washer. Do not tighten the bolt. (See Illustration 1 - Part 3 of 5, Section B-B).

10. Slide (2) 688438 Spacers under the rear bracket on the left side of engine that holds number 7, 9, and 11 fuel lines. Install new 0L2070 Bolts [57.2 mm (2.25 in)] with new 9X6458 Washers. Do not tighten the bolts. (See Illustration 1 - Part 5 of 5, Section D-D).

11. Slide (2) 8T1296 Washers under the front bracket on the left side. The bracket holds number 7, 9, and 11 fuel lines. Install new 0S1590 Bolts [50.8 mm (2.0 in.)] with new 9X6458 Washers. Do not tighten the bolts. (See Illustration 2).

12. Install new 0S1590 Bolts [50.8 mm (2.0 in.)] and new 9X6458 Washers for the fuel line brackets on the right side of engine. Do not tighten the bolts.

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. If they are too thick or thin, use the 9X6458 Washers saved from Step 2 along with the 8T1296 Washers and 688438 Spacers as needed to fill the gaps. The purpose of the spacers and washers is to prevent the brackets/clamps from putting unwanted strain on the fuel lines.

13. Tighten all of the bracket mounting bolts.

14. Using (2) new 5P4939 Screws, install (1) 9Y3357 Clamp and (1) 102-9228 Clamp Assembly on number 2 and 6 fuel lines. Tighten the screws to a torque of 2.25 ± .25 N·m (20 lb.in.). See Illustration (3).

15. Remove (2) 1W9169 Clamps, (2) 9N3388 Screws, (2) 1W9167 Clamp Assemblies, (2) 4B4274 Washers and (1) 9Y7524 Plate on Number 2 and 8 fuel lines. See Illustration 4.

16. Use the hand priming pump to purge air out of the fuel lines. The fuel line nuts at the adaptors in the valve cover bases may need to be loosened to allow the air to escape. Tighten the fuel line nuts finger tight as the air is purged from each line.

17. Tighten all of the fuel line nuts to a torque of 40 ± 7 N·m (30 ± 5 lb.ft.).

18. Wipe up all spilled fuel.

19. Start the engine to purge any remaining air from the fuel lines. Make sure there are no fuel leaks.

20. Shut the engine off and tighten the fuel line nuts again to the torque shown above.

21. Paint the fuel lines and clamps around the tower clamp assembly, then touch up all the fuel lines, clamps, and brackets as necessary.

Group 2 Procedure

1. Remove the 9Y3361 Bracket (Front V Bracket). Replace with new 6I0347 Bracket. Use new (2) 9N3388 Screws, (2) 4B4274 Washers, and (2) 7C6591/7C7747 Clamps to attach fuel line to the bracket. (See Illustration 1 - Part 1 of 5). Tighten screws to a torque of 20 N ·m (20 lb. in.).

2. Remove the 2 line metal-to-metal fuel line clamp or 2 line damper clamp that holds line 4 and 6 (See all parts of Illustration 1). Replace with 6I4813 Clamp Kit. Be sure to use an 8T1296 Washer between the plate and aftercooler housing.

3. Using (2) new 5P4939 Screws, install (1) 9Y3357 Clamp and (1) 102-9228 Clamp Assembly on number 2 and 6 fuel lines. Tighten the screws to a torque of 2.25 ± .25 N·m (20 lb.in.). See Illustration (3).

4. Remove (2) 1W9169 Clamps, (2) 9N3388 Screws, (2) 1W9167 Clamp Assemblies, (2) 4B4274 Washers and (1) 9Y7524 Plate on Number 2 and 8 fuel lines. See Illustration 4.

Group 3 Procedure

1. Using (2) new 5P4939 Screws, install (1) 9Y3357 Clamp and (1) 102-9228 Clamp Assembly on number 2 and 6 fuel lines. Tighten the screws to a torque of 2.25 ± .25 N· m (20 lb.in.). See Illustration (3).

2. Remove (2) 1W9169 Clamps, (2) 9N3388 Screws, (2) 1W9167 Clamp Assemblies, (2) 4B4274 Washers and (1) 9Y7524 Plate on Number 2 and 8 fuel lines. See Illustration 4.

Illustration 1 - Part 1 Of 5

Illustration 1 - Part 2 Of 5

Illustration 1 - Part 3 Of 5

Illustration 1 - Part 4 Of 5

Illustration 1 - Part 5 Of 5

Illustration 2

Illustration 3

Illustration 4