PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 255-2955 FUEL LINE AND 244-7592 FUEL TUBE ON CERTAIN 365CL, 365CL MH, 365CL FS, AND 365CL OEM HYDRAULIC EXCAVATORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 255-2955 FUEL LINE AND 244-7592 FUEL TUBE ON CERTAIN 365CL, 365CL MH, 365CL FS, AND 365CL OEM HYDRAULIC EXCAVATORS [REBE3842]

FUEL SYSTEM

FILTER GP-FUEL

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 255-2955 FUEL LINE AND 244-7592 FUEL TUBE ON CERTAIN 365CL, 365CL MH, 365CL FS, AND 365CL OEM HYDRAULIC EXCAVATORS

REBE3842-00

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27Jun2008

U-343

A-278

D-282

O-311

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 255-2955 FUEL LINE AND 244-7592 FUEL TUBE ON CERTAIN 365CL, 365CL MH, 365CL FS, AND 365CL OEM HYDRAULIC EXCAVATORS
1274 1261		PI31522

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31522" 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 "PI31522" 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 AVSpare product analyst.

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COMPLETION DATE	TERMINATION DATE
31Dec2008	30Jun2009

PROBLEM

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A fuel leak may result from the existing fuel hose configuration allowing the fuel hose to rub against the 236-9862 Breather Tube and/or the 239-5929 Engine Harness on certain 365CL, 365CL MH, 365CL FS, and 365CL OEM Hydraulic Excavators.

A fuel leak may result from the existing fuel tube configuration allowing the fuel tube to rub against the 6V3265 P-Clip.

AFFECTED PRODUCT

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Model	Identification Number
365C L	ELC00156-00439 MCS00178-00191, 193-482, 484 MCY00185-00457, 459 MEM00171-00274
365C L FS	PAR00250-00269
365C L MH	GWC00226-00228
365C L OEM	GSZ00101-00103, 116-134
CIPI	0EM01312-01313, 1397, 1417, 1479, 1674-1675, 1682, 1960-1961, 1972-1973

PARTS NEEDED

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Qty	Part Number	Description
2	0S1619	BOLT
2	2R6806	CONNECTOR
2	7V6571	GROMMET
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
2	8T4121	WASHER-HARD
2	8T4136	BOLT
2	0336042	SEAL-O-RING
1	1165263	HOSE AS
1	1629728	BRACKET AS.
1	1680300	MANIFOLD
1	1688974	TUBE AS
1	2822593	BRACKET AS.
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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The 255-2955 fuel line and 244-7592 fuel tube need to be replaced on certain 365CL, 365CL MH, 365CL FS, and 365CL OEM Hydraulic Excavators.

Refer to the attached Rework Procedure.

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OWNER NOTIFIAVSION

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

SERVICE CLAIM ALLOWANCES

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AVSpare		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 3.0-hour job

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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 NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE 255-2955 FUEL LINE AND 244-7592 FUEL TUBE ON CERTAIN 365CL, 365CL MH, 365CL FS, AND 365CL OEM HYDRAULIC EXCAVATORS

MODELS INVOLVED - 365CL, 365CL MH, 365CL FS, and 365CL OEM Hydraulic Excavators

Dear AVSpare Product Owner:

The 255-2955 fuel line and 244-7592 fuel tube need to be replaced on certain 365CL, 365CL MH, 365CL FS, and 365CL OEM Hydraulic Excavators. A fuel leak may result from the existing fuel hose configuration allowing the fuel hose to rub against the 236-9862 Breather Tube and/or the 239-5929 Engine Harness. A fuel leak may result from the existing fuel tube configuration allowing the fuel tube to rub against the 6V3265 P-Clip.

Contact your local AVSpare 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 27Jun2008 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.

AVSpare Inc.

Identification #(s)

Attached to 27Jun2008 Service Letter

Rework Procedure

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-Remove the left two front engine lifting eye mounting bolts.
-Loosen the right two front engine lifting eye mounting bolts.

Image1.1.1

-Remove the ladder clip supporting the engine harness and rotate the lifting eye out of the way.
-Undo the compression nut holding the front of the fuel line to the cylinder head.

Image1.2.1

-Remove the bolt securing the P clip to the back of the front gear housing.

Image1.3.1

-The steel tube is connected to a hose. Remove the P clip that secures the hose to the cylinder head and remove the hose from the filter base. Keep the bolt and washer used to secure the p-clips for re-use.
-Do not reuse the old tube and hose.

Image1.4.1

-Remove the two bolts and spacers that hold the front housing bracket to the head. Refer to image 1.5.1
-Do not reuse the bolts and spacers. Keep the washers for reuse.
-Using the new 0S-1619 bolts and the washers that were saved, install the 168-0300 Fuel Manifold to the head. See image 1.5.2
-Once the manifold is bolted to the head, install one 033-6042 o-ring each to two of the 2R-6806 connectors. Install one connector to the top of the manifold and one connector to the bottom. See image 1.5.3
-Install the new 168-8974 fuel tube to the top connector and to the cylinder head.
-Reinstall the bolts for the lifting eye and the ladder clip bracket.

Image1.5.1

Image1.5.2

Image1.5.3

-Refer to the Hydraulic Information System in SIS Web in order to construct the 116-5263 fuel hose assembly.
-Once the 116-5263 fuel hose has been made, connect one end to the bottom connector on the 168-0300 manifold previously installed.
-Route the 116-5263 Fuel hose behind the Inlet Manifold Pressure sensor harness and behind the ether line, if present. Also, route the fuel hose to the outside of the breather tube.

Image1.6.1

-Connect the hose to the fuel filter base.
-Install the 162-9728 bracket to the bottom right bolt of the intake air tube.
-Assemble the 2 piece clip, grommet, bolt, and washer (8T-1889, 8T-1890, 7V-6571, 8T-4136 and 8T-4121) to the 162-9728 bracket and 116-5263 fuel hose