Product Support Program For Installing New Fuel Pressure Bypass Valve And Improved Fuel Filter On Certain E110B, E120B, E200B, EL200B, E240B, EL240B, E240C, EL240C, 320, 320 L, 325, And 325 L Excavators; 446 Backhoe Loaders; CS563 And CP563 Compactor Caterpillar

Product Support Program For Installing New Fuel Pressure Bypass Valve And Improved Fuel Filter On Certain E110B, E120B, E200B, EL200B, E240B, EL240B, E240C, EL240C, 320, 320 L, 325, And 325 L Excavators; 446 Backhoe Loaders; CS563 And CP563 Compactor

Usage:

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Caterpillar: Confidential Yellow

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 "PS4730" 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 October 4, 1992 Service Letter. Changes have been made to the Affected Product.

Termination Date

October 31, 1994

Problem

Certain E110B, E120B, E200B, EL200B, E240B, EL240B, E240C, EL240C, 320, 320 L, 325, and 325 L Excavators; 446 Backhoe Loaders; CS563 and CP563 Compactors; IT12B and IT14B Toolcarriers; 910E and 950F Loaders; and 3114 and 3116 Engines may experience hard starting when the engine is warm. This problem may result from internal wear on the scroll-edge of the fuel injector plunger. The wear is caused by very fine dirt in the fuel going through the filter when it becomes plugged, and by the practice of pre-filling the fuel filter with contaminated fuel before installing it.

Affected Product
Model & Identification Number

Group 1 - Before / After Failure
Install Fuel Bypass Valve, Filter Base And Filter

E110B (8MF1-388, 8MF393)

E120B (6JF1-754 6JF789-790, 6JF812, 6JF816)

E200B (6KF1-1182, 6KF1188; 6KG1-392)

EL200B (7DF1-1887, 7DF1990-2014, 7DF2016)

E240B (8SF1-93; 9PF1-486, 9PF488, 9PF489)

EL240B (5WG1-715, 5WG717, 5WG726, 5WG728, 5WG737; 6MG1-211)

325 (2JK1-182; 1TG1-73)

446 (6XF1-Up)

CP/CS563 (8XF1-Up)

IT12B (1KF1-Up)

IT14B (3NJ1-Up)

910E (1SF1-Up)

950F (2XK1-Up; 4DJ1-Up; 7ZF1-Up; 6YG1-Up)

3114^* (5JG1-Up; 6AF1-Up; 1NJ1-Up)

3116^* (2SG1-Up; 2WG1-Up; 1SK1-Up; 4KG1-Up)

^*The 3114 and 3116 Industrial, Gen Set, and Marine engines should not have the 3-micron filter installed, unless the unit is actually sold and operating in CFEL territory. For example, many 3116 Marine engines are sold to boat manufacturers who then export the boat to the USA or other parts of the world. In these cases, inventory units should NOT be updated.

Group 2 - Before / After Failure
New Fuel Filter & Fuel Filter Base Required

E110B (8MF389-392; 5GK1-88)

E120B (6JF755-788; 4XK1-99)

E200B (6KF1183-1187, 6KF1189-Up; 6KG393-Up)

EL200B (7DF1888, 7DF1889, 7DF2015, 7DF2017-Up)

E240B (8SF94-Up; 9PF487, 9PF490-Up)

EL240B (5WG716, 5WG718-725, 5WG727, 5WG729-736, 5WG738-755; 6MG212-Up)

E240C (2RL1-107)

EL240C (9PK1-760)

320 & 320 L (2XK1-522, 2XK524-537, 2XK543, 2XK547; 4ZJ1-392, 4ZJ397; 9WG1-444; 7WK1-55; 1TL1-180)

325 & 325 L (8JG1-166; 7CJ1-448; 9SG1-186; 7LJ1-247, 7LJ250; 2SK1-218, 2SK253, 2SK266)

Parts Needed

There are two groups of Affected Product. The Group 1 Affected Product need the complete update, consisting of the new fuel bypass valve and lines, and the new fuel fuel filter base and 3-micron filter. The Group 2 Affected Product need only the new fuel filter base and filter, because they already have the new bypass valve parts installed at the factory.

Group 1 - Before / After Failure
Install Fuel Bypass Valve, Filter Base And Filter

1 - 7C1159 Gasket

1 - 3E7410 O-Ring Tee

^*1 - 7E9898 Connector (See Illustration 1)

1 - 6I2421 Tube Assembly

1 - 6I2422 Bypass Valve Assembly

1 - 6I4783 Fuel Filter

1 - 6I4802 Base Assembly

6 - 3J1907 O-Ring Seal

1 - 4K8864 Clip

1 - 8L5449 Spacer

1 - 9M1974 Washer

2 - 5P1046 Connector

70 cm - 5P1442 Hose

2 - 5P4961 Hose Clamp

1 - 8T0788 Elbow

1 - 6V5219 Bolt

4 - 6V8397 O-Ring Seal

1 - 6V8774 Face Seal Tee

^*Use new connector only on earlier engines with fuel line (1), connector, and elbow in the governor as shown in Illustration 1. Later engines have a different fuel line (1) shown in Illustration 2, and do not need the new connector.

Group 2
New Fuel Filter And Base Required

1 - 7C1159 Gasket

1 - 6I4783 Filter (3-Micron)

1 - 6I4802 Base Assembly

2 - 3J1907 O-Ring Seal

2 - 6V8397 O-Ring Seal

Group 1 & 2 - Additional Parts - After Failure
Hard Starting When The Engine Is Warm

1 -^* Injector

^*Part number varies by application. Use as required, one per cylinder.

Action Required

See the attached procedure.

Service Claim Allowances

Parts Disposition

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

Attach. (1-Rework Procedure)

Rework Procedure

Group 1 - Before Or After Failure
Install Fuel Bypass Valve, Filter Base And Filter

1. Remove 7E6288 or 7W0032 Tube Assembly (1) from the transfer pump to the fuel filter. Remove the 6V8724 Elbow (2) in the fuel filter base. Remove the existing fuel filter base and fuel filter.

NOTE: For earlier engines which have 7W0032 Tube Assembly (1) and 6V8724 Elbow (2) as shown in Illustration 1, the 6V8724 Elbow (3) and 7W7381 Fitting (4) at the governor housing must also be removed, and replaced by a new 7E9898 Connector (6). Take care not to disturb or damage the small check valve in the governor housing under the connector.

Later engines with 7E6288 Tube Assembly (1) and connector (6) as shown in Illustration 2 already have the correct connector in the governor housing.

2. Disconnect the fuel return hose and its elbow (5) temporarily.

3. Install the new 3E7410 Tee (7) and 5P1046 Connector (8) at the governor as shown in Illustration 3. Install the 5P4924 Elbow (5) into the new tee and connect the fuel return hose back to the elbow.

4. Install the new 6I4802 Filter Base, using 7C1159 Gasket. Install 8T0788 Elbow (9) at the fuel filter. Install the new 6I2421 Tube Assembly (10), 6V8774 Tee (11) , and 6I2422 Bypass Valve Assembly (12) to 8T0788 Elbow (9) at the fuel filter. Refer to Illustration 3.

NOTE: The 6I2422 Bypass Valve Assembly must be installed exactly as shown in Illustration 3, with Plug (A) directly opposite Tee (11). It is possible to install the valve incorrectly, with Plug (A) up. In that position, the bypass valve is backwards and will not function.

5. Install 5P1046 Connector (13) to bypass valve assembly (12) and 5P1442 Hose (14) to connectors (8) and (13) with 5P4961 Clamps (15) as shown in Illustration 3. Remove existing bolt and mount the bypass hose with 8L5449 Spacer (16) , 4K8864 Clip (17) , 9M1974 Washer (18) , and 6V5219 Bolt (19) on cylinder block cover as shown in View B-B. Check hose routing to make sure they will not be rubbed or cut. Tighten the bolt to 25 ± 7 N · m (18 ± 5 lb ft).

6. Install new 6I4783 Filter (20). Paint parts after assembly to prevent rust of new valve, fuel line, and other parts.

NOTE: Be sure to inform the customer of the following:

a) The new filter will filter out much smaller particles than the former filter in order to protect the fuel injectors from possible wear. For that reason, customers should use only the new 6I4783 Filter. Former filters will not fit the new filter base.

b) Fuel filters should be installed DRY and primed with the hand priming pump. Do not fill the fuel filter with fuel before installing it. This fuel would not be filtered and could be contaminated. Contaminated fuel will cause accelerated wear to the fuel system parts. For example, some users have filled fuel filters from the fuel tank drain.

This fuel can be severely contaminated by dirt, rust, water, and other debris. Water and sediment should be drained from the fuel tank each day.

c) Also, the recommended fuel filter change interval is 250 hours. More frequent filter changes may be required if it becomes plugged from dirt, rust, or other debris. Plugged fuel filters are indicated by low power, poor performance, and/or black smoke. Filter life will depend on fuel quality.

7. Use the hand-priming pump to fill the fuel filter. Then, start the engine and check for leaks.

Group 2
New Fuel Filter And Base Required

1. Remove existing fuel filter base, gasket, and fuel filter.

2. Install new 6I4802 Filter Base, using 7C1159 Gasket. Connect the fittings and fuel lines.

3. Continue with steps 6 and 7 from the Group 1 procedure.

Groups 1 & 2 - After Failure Hard Starting When The Engine Is Warm

Replace the injectors only if the Affected Product is currently experiencing hard starting problems with a warm engine due to injector wear. If the engine is hard to start only when the engine is cold, worn injectors are probably not the cause, and injector replacement is not authorized under this program.

1. Replace injectors. Use remanufactured injectors, if available. Before installing new injectors, clean carbon deposits from the lower injector sealing surface of brass sleeve in the cylinder head using a 4C5553 Brush (tapered or cone-shape) and 4C5570 Brush (small bore brush-straight). These brushes are part of 4C4462 Sleeve Replacement Tool Group, and also part of 4C8711 Reaming Kit. Brushes are also available separately. Do not scratch or gouge the sealing surface of the sleeve in the cylinder head.

2. Synchronize the injectors. Set Fuel Timing. Refer to the Testing and Adjusting Module in the Service Manual for procedures and tools.

3. When injectors are replaced, use the hand priming pump to purge air from the fuel filter and cylinder head. Start the engine and check for leaks and proper operation.

Illustratin 1 - Engine With 7W0032 Tube Assembly