PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INJECTION PUMP ON CERTAIN 3412C GENERATOR SETS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INJECTION PUMP ON CERTAIN 3412C GENERATOR SETS

Usage:

SEBE9540

April 3, 2006
U-101
O-88

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE INJECTION PUMP ON CERTAIN 3412C GENERATOR SETS
1251		PI30918

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30918" 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 "PI30918" 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.

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COMPLETION DATE	TERMINATION DATE
October 31, 2006	April 30, 2007

PROBLEM

The rack bar 4P-7326 has a slot machined in it that is not to print. The slot is too narrow. This causes the bar inserted in the slot to bind up and impair the rack movement. We have traced the rack bars from the twenty-three sticky rack failures and they all fall into two Woodward manufacturing lots. The 168 injection pumps built with the two suspect rack bar lots are in the serial range from 14415965 to 14446549.

FG Wilson, with an injection pump in the suspect serial number range. Suspect injection pumps will be returned to Woodward for rework. Engines in the field will be handled in an alternative manner. Unfortunately, it is not acceptable to change the injection pump and not re-dyno test the engine. The plan is to remove and replace the injection pump on any engine or generator-set in house, including engine.

AFFECTED PRODUCT

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Model	Identification Number
3412C	DJN758-762, 790, 796-797, 802-805, 807, 809-811, 813, 815, 820-821 TFT441

PARTS NEEDED

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Qty	Part Number	Description
*	6I-2358	Injection Pump

*NOTE: Order only if needed after the inspection has been completed.

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

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.
100%	6.5	0	0	0	0
NOTE: This is a 5.0 hr job for the pump relplacement. An additonal 1 hr segment will also be added to the labor hours to account for dyno testing an engine that has had the fuel injection pump replaced. *NOTE: An additional 0.5 hrs will be allowed for inspection per engine.

PARTS DISPOSITION

NOTE: All dealers are to make sure the outside of the shipping container is marked with the service letter number. ***** All Dealers *****

Return all defective 6I-2358 injection pumps removed from engines. Also send in a copy of the claim to:

Caterpillar Inc.
Attn: Supplier Recovery
Service Claims Room
8201 N. University
Peoria, IL 61615

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

Attach. (1-Owner Notification)
(2-Rework Procedure)

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 INJECTION PUMP

MODELS INVOLVED - CERTAIN 3412C GENERATOR SETS

Dear Caterpillar Product Owner:

The injection pump needs to be inspected and possibly replaced on the products listed below. 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 April 3, 2006 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 April 3, 2006 Service Letter

Rework Procedure

Inspection: