PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL INJECTION PUMP OUTLET CHECK PLUGS ON CERTAIN C7 AND C9 ON-HIGHWAY TRUCK ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL INJECTION PUMP OUTLET CHECK PLUGS ON CERTAIN C7 AND C9 ON-HIGHWAY TRUCK ENGINES

Usage:

REBE4252-01

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22Aug2008

(Revised 02Sep2008)

U-440

A-359

D-363

O-400

TT-30

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL INJECTION PUMP OUTLET CHECK PLUGS ON CERTAIN C7 AND C9 ON-HIGHWAY TRUCK ENGINES
1288 1251 1290 1714		PI10707

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10707" 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 "PI10707" 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:	This Revised Service Letter replaces the 22Aug2008 Service Letter. Changes have been made to Action Required to add Special Instruction references.

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PROBLEM

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This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act, and the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in 2008 and 2009 model year trucks and buses equipped with certain Caterpillar C7 and C9 diesel engines.

A fuel pump plug may crack, which could cause fuel to spray and leak. Fuel in the presence of an ignition source can result in a fire. The driver may also become aware due to decrease in engine power or the illumination of a check engine lamp or engine protection lamp. New fuel pump plugs will be installed on the engine. You will not be charged for the service performed. It is a violation of US Federal law for a dealer to deliver a new motor vehicle or new or used engine covered by this Safety PIP until the PIP has been completed.

AFFECTED PRODUCT

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Model	Identification Number
C7	C7S00500, 514-515, 520-527, 531, 534, 536-537, 543, 548, 553, 557-1375, 1377-1379, 1382-1383, 1385, 1387-1396, 1398-1407, 1409-1459, 1461-1467, 1469-1474, 1479, 1481-1483, 1485, 1487-1494, 1496-1497, 1500-1508, 1511-1566, 1568-1592, 1594-1610, 1612-1615, 1617-1944, 1946-2223, 2228, 2239, 2243, 2252, 2261-2262, 2264-2266, 2274, 2276, 2279, 2283, 2285-2286, 2289-2290, 2293, 2296, 2301-2792, 2794-2796, 2799-2800, 2802, 2804-2806, 2808-2811, 2814-2816, 2819-2820, 2822, 2825, 2827-2828, 2830-2836, 2839-2841, 2843-2846, 2848, 2850-2851, 2853, 2856-2858, 2863, 2868, 2874-2939, 2941-2953, 2955-3755, 3760, 3767-3768, 3778, 3785, 3787, 3790, 3799-3800, 3805-3807, 3809, 3813, 3816, 3820, 3823, 3828-3829, 3836, 3841, 3848, 3856, 3864-3865, 3868-3894, 3896-3902, 3904-3912, 3917, 3922, 3925, 3927, 3929-3930, 3932-3933, 3935-3936, 3938, 3940-3941, 3943-3946, 3949, 3952-3955, 3958-3959, 3964-3969, 3971, 3973-3977, 3979, 3981-3982, 3985, 3988-3992, 4433-4995, 4999, 5001-5002, 5004-5005, 5007-5033, 5038, 5047, 5049-6167, 6169-6181, 6183-6184, 6186-6199, 6201-6204, 6206-6208, 6210-6212, 6215-6216, 6218-6226, 6228-6230, 6232-6250, 6252-6253, 6255-6263, 6265, 6268-6331, 6333-6335, 6337-6338, 6340-6343, 6345-6356, 6358-6381, 6386-6388, 6390-7450, 7480-8985, 8988-9098, 9100-9142
C9	C9S00500-00507, 522-523, 527, 531, 534-661, 664, 666, 668, 673-738, 740-741, 746-754, 756-762, 771, 782-841, 849-850, 852, 854-896, 898-902, 907-1006, 1009, 1015, 1017-1021, 1028-1032, 1034-1205, 1209-1319, 1324, 1328-1377, 1380-1381, 1394-1507, 1509, 1511, 1515-1516, 1518-1529, 1536, 1540 MFF00303-00316, 329-369, 372-375

PARTS NEEDED

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Qty	Part Number	Description
1	3106027	KIT-LINES F INJ (As Needed see Action Required)
1	3106029	KIT-LINES F INJ (As Needed see Action Required)
1	3106030	KIT-LINES F INJ (As Needed see Action Required)
1	3106031	KIT-LINES F INJ (As Needed see Action Required)
1	3106032	KIT-LINES F INJ (As Needed see Action Required)
1	3106033	KIT-LINES F INJ (As Needed see Action Required)
1	3348053	KIT-OUTLET CHECK
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. NOTE: Fuel Lines replacement is Inspect and Possibly Replace as described in the Action Required.

ACTION REQUIRED

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Check Plug Replacement:

1) Check engine serial number to ensure it is included in the affected rework population.

2) Inspect fuel injection pump outlet check plugs installed on pump. Refer to Image1 for check plug location. If the fuel injection pump outlet check plugs have dimples as shown in Image2 DO NOT perform plug rework.

3) If check plugs do not have dimples as shown in Image2 the plugs need to be replaced, refer to Special Instructions REHS3841 for proper plug installation.

Fuel Line Inspect and Possibly Replace:

Refer to Special Instructions REHS3842 for C7, and REHS3846 for C9. Inspect all high pressure fuel lines that require clamping to ensure proper clamping location and torque for each clamp that holds each high pressure fuel line in place. Verify all rubber grommets are present in each clamp. The fuel line(s) must be replaced if the clamp location/torque and or the grommets are not correct.

Reference line kit part numbers below for C7 and C9 if needed after inspection is complete.

DESCRIPTION______________________KIT

C7
Tube As.-Fuel_(Pump Line)______310-6027
Tube As.-Fuel_(Line 1)_________310-6029
Tube As.-Fuel_(Line 6)_________310-6030

C9
Tube As.-Fuel_(Pump Line)______310-6031
Tube As.-Fuel_(Line 1)_________310-6032
Tube As.-Fuel_(Lines 5 & 6)____310-6033

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Image1

Image2

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

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NOTE: This is a 1.0-hour job
Add an additional 0.2 Hrs per high pressure fuel line replaced in step 4 in the Action Required if needed.

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PARTS DISPOSITION

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

Only return high pressure fuel line(s) replaced during this rework to the address below.

NOTE: Make sure the outside of the shipping container is marked PIXXXX.

Caterpillar Inc.
Attn: PIXXXXX
Route 29 And Old Galena Road
Building DD, Dock 8,Engineering Parts Return Area
MOSSVILLE, IL 61552
USA

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

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IMPORTANT: SAFETY NOTICE

SAFETY ? RECALL FOR REPLACING THE FUEL PUMP PLUGS

MODELS INVOLVED - Certain C7 and C9 Truck and Bus Engines

Dear Caterpillar Product Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act, and the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in 2008 and 2009 model year trucks and buses equipped with certain Caterpillar C7 and C9 diesel engines.

A fuel pump plug may crack, which could cause fuel to spray and leak. Fuel in the presence of an ignition source can result in a fire. The driver may also become aware due to decrease in engine power or the illumination of a check engine lamp or engine protection lamp. New fuel pump plugs will be installed on the engine. You will not be charged for the service performed.

Please contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired for this concern prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own a vehicle with this engine, please contact Caterpillar at this toll free number (800) 447-4986.

If the dealer is unable to have the repair made, please contact:

Caterpillar Inc.
PO Box 610
Mossville, IL 61552-610
Attn: Engine Products Division
Truck Engine Call Center
Telephone: (800) 447-4986

If you are still unable to have the repair made within 60 days or without charge, you may submit a complaint to:

In the U.S.
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov

In Canada
Transport Canada
Road Safety and Motor Vehicle Regulation
Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851
Caterpillar Inc.

Please refer the dealer to their Service Letter dated 22Aug2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 22Aug2008 Service Letter