PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A VIBRATION DAMPER TO THE 305-7304 FUEL PIPE ON CERTAIN D6N XL, D6N LGP, D6K XL, AND D6K LGP TRACK TYPE TRACTORS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A VIBRATION DAMPER TO THE 305-7304 FUEL PIPE ON CERTAIN D6N XL, D6N LGP, D6K XL, AND D6K LGP TRACK TYPE TRACTORS

Usage:

REBE4590-01

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09Dec2008

(Revised 22Dec2008)

U-631

O-575

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING A VIBRATION DAMPER TO THE 305-7304 FUEL PIPE ON CERTAIN D6N XL, D6N LGP, D6K XL, AND D6K LGP TRACK TYPE TRACTORS
1274		PI31595

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31595" 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 "PI31595" 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 09Dec2008 Service Letter. Changes have been made to add Group 2, the Affected Product to add WGS serial number prefix, and to the Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
30Jun2009	31Dec2009

PROBLEM

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Vibration from the 305-7304 Fuel Pipe can cause fatigue of the fuel injection pump inlet connector.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
D6K LGP	DHA00207-00227, 229-239, 241-242, 244-262, 264, 266-267, 269-274, 276-285, 287-304, 306-311, 313-335, 337-349, 351-360, 362-367, 369-377, 379-381, 383-386, 388-405, 407-412, 414-432, 434-442, 444-529, 531-565, 567-606, 608-624, 626-637
D6K XL	FBH00329-00389, 391-442, 444-577, 579-615, 617-651, 653-684, 686-704, 706-710, 712-769, 771-788
D6N LGP	DJY00121-00126, 128-133, 135-137, 139-157, 159-161, 163-166, 168-189, 191-214, 216-217, 219-244, 246-256, 258-268, 270-280, 282-286, 288-292, 294-301, 303-304, 306-341, 343-361, 363-367, 369-377, 379-418, 420-424, 426-445, 447-448, 450-454, 456-460, 462-494, 496-516, 518-530, 532-541, 543-565, 567-568, 570-597, 599-641, 643-665, 668-676, 678-684, 686-715, 717-733, 735-742, 745, 747-748, 751-753, 755-756, 758-767, 769-780, 783-788, 790-791, 793-798, 800-804, 806-822, 824-836, 838-839, 841-867, 869-886, 888-899, 901
D6N XL	DJA00231-00290, 292-347, 349-355, 357-365, 368-380, 382-396, 398-399, 401-409, 411-437, 440-461, 463-523, 525-532, 534-585, 587-596, 598-617, 619-631, 633-641, 643-682, 684-687
PL61	WGS00100-00101

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*****Group 2*****
D6K XL	NCF00001-00043

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	3379558	SLEEVE-DAMPER
1	3398785	ISOLATOR RUBBER
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.
*****Group 2*****
1	3379558	SLEEVE-DAMPER
1	3398785	ISOLATOR RUBBER
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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Install a 339-4957 Bushing and 336-9848 Sleeve to act as a vibration damper to remove the vibration from the fuel pipe assembly.

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%
*****Group 1*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
100%	100%	0%	0%	0%	0%

NOTE: This is a 1.5-hour job for Group 2

PARTS DISPOSITION

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 INSTALLING A VIBRATION DAMPER TO THE 305-7304 FUEL PIPE ON CERTAIN D6N XL, D6N LGP, D6K XL, AND D6K LGP TRACK-TYPE TRACTORS

MODELS INVOLVED - D6N XL, D6N LGP, D6K XL, and D6K LGP Track-Type Tractors

Dear Caterpillar Product Owner:

The stainless steel fuel pipe between the third fuel filter and fuel injection pump needs to have a vibration damper fitted on the products listed below. In some cases the fuel pipe vibrates excessively causing fatigue of the fuel pump inlet connector. The vibration damper will remove any excessive vibration. 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 09Dec2008 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 09Dec2008 Service Letter

Rework Procedure

Installation of Vibration Damper

Tools and Parts Required

339-8785 Rubber Bushing
337-9558 Metal Sleeve
Hand soap (To assist installation)

Process for Installing the rubber vibration damper

1. Remove primary fuel filter and set aside to gain access to the low pressure fuel pipe, (place filter in a clean plastic bag to remove risk of contamination of the fuel system, see image 1.1.1.). If possible, avoid disconnecting Low Pressure and High Pressure fuel pipes. If any fuel pipes do have to be disconnected then follow the existing fuel system service procedures, (SMCS 1260-010)

Image1.1.1

2. Image 1.2.1. shows the location on the fuel pipe, with the primary filter removed, where the damper is to be fitted (as indicated by point 3).

3. Install the 339-8785 Rubber Bushing on the fuel pipe. See Image 1.3.1.

Image1.3.1

4. To aid assembly, apply soap solution to the inside of the 337-9558 Steel Sleeve prior to installing around the fuel pipe and bushing as indicated in Image 1.4.1.

Image1.4.1

5. Move the sleeve around the fuel pipe towards the rubber bushing ensuring that the slot in the sleeve is directly opposite the joint in the bushing as indicated in Image 1.5.1.

Image1.5.1

6. Push the sleeve over the rubber bushing, working the rubber into the sleeve until it is located centrally to the bushing as indicated in image 1.6.1.

Image1.6.1

7. Ensure the loom and loom support plate is clear of the bushing, adjust the pipe clip and move the damper away from the plate as necessary (See image 1.7.1.).

Image1.7.1

8. Replace the primary fuel filter, removing any external fuel spillage, and reassemble engine components.

9. On completion of the assembly, run the engine and check to be sure there are no leaks from the fuel filter.