938H - JKM - PI31638.pdf

Service Letter PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL PIPE ON CERTAIN 938H WHEEL LOADERS AND IT38H INTEGRATED TOOLCARRIERS

REBE4858-00

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Media Number -REBE4858-00 Publication Date -26/02/2009 Date Updated -26/02/2009

CONFIDENTIAL

26Feb2009

Priority

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL PIPE ON CERTAIN 938H WHEEL LOADERS AND IT38H INTEGRATED TOOLCARRIERS

1274 1261 127A 1252 PI31638

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI31638" 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 "PI31638" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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: 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

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PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

OWNER NOTIFICATION

without first contacting your Caterpillar product analyst.

COMPLETION DATE TERMINATION DATE 31Aug2009 28Feb2010

There is evidence of twisting of the pipes at the final bend adjacent to the pipe flange. In some instances the twisting can cause a fatigue crack to occur in the pipe.

Model Identification Number

938H JKM00151-00646, 655, 667, 669, 687, 714, 720-721

LKM00135-00280, 282-346, 352, 393

MJC00047-00506

IT38H JNJ00151-00334, 337, 343, 345, 350, 354

Qty Part Number Description

1 6V8397 SEAL-O-RING

1 2784138 PROTECTION KT

1 3381398 TUBE PUMP-FILTER

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.

Replace the existing pipe with a similar pipe of new design.

Refer to the attached Rework Procedure.




SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

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

Caterpillar Dealer Suggested Customer Suggested

Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%

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

NOTE: This is a 1.0-hour job

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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 PIPE ON CERTAIN 938H WHEEL LOADERS AND IT38H INTEGRATED TOOLCARRIERS

MODELS INVOLVED - 938H Wheel Loaders and IT38H Integrated Toolcarriers

Dear Caterpillar Product Owner:

The fuel pipe needs to be replaced on the products listed below. The existing pipe can crack. You will not be charged for the service performed.

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 26Feb2009 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.




Rework Procedure

Caterpillar Inc.

Identification #(s)

Attached to 26Feb2009 Service Letter

NOTE: Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to System Operation, Testing and Adjusting, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

NOTE: Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates.

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 components that are 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.




1. Open hood.

2. Drain fuel from primary fuel filter into a suitable container for storage or disposal.

3. Disconnect fuel lines and harness at primary fuel filter. Plug/cap fuel lines and ports on filter head.

Image1.2.1

4. Remove primary fuel filter.




Image1.3.1

5. Disconnect fuel lines from secondary fuel filter. Plug/cap fuel lines and ports on filter head. Remove secondary fuel filter assembly.

Image1.4.1

6. Remove secondary fuel filter bracket.




Image1.5.1

7. Remove low pressure fuel supply tube from connector at fuel injection pump supply port. Install 338-1398 low-pressure fuel supply tube and 6V-8397 O-ring seal to connector at fuel injection pump supply port. Tighten swivel nut to torque of 43 +5/-0 N-m.

Image1.6.1




8. Install filter mounting bracket and secondary fuel filter assembly.

9. Connect 338-1398 fuel supply tube and 6V-8397 O-ring seal to connector at secondary fuel filter. Tighten swivel nut to torque of 43 +5/-0 N-m.

10. Reconnect fuel lines to secondary fuel filter.

11. Install primary fuel filter and reconnect fuel lines.

12. Connect harness to electric fuel priming pump. Prime the fuel system as describe in 938H/IT38H Operation and Maintenance Manual (Media #REHS8079).

13. Check for leaks and remedy as necessary.

14. Close hood.

Copyright 1993 - 2009 Caterpillar Inc.

All Rights Reserved.

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Fri Feb 27 15:06:26 UTC-0300 2009




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938H - JKM - PI31638.pdf

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