PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND TORQUEING THE GOVERNOR SHAFT BOLT FOR CERTAIN 3406 ENGINES. Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND TORQUEING THE GOVERNOR SHAFT BOLT FOR CERTAIN 3406 ENGINES.

Usage:

REBE1328-00

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07Nov2006

A-687

D-672

O-698

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND TORQUEING THE GOVERNOR SHAFT BOLT FOR CERTAIN 3406 ENGINES.
1288 7418 1264 1286		PI10553

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10553" 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 "PI10553" 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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PROBLEM

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A bolt, internal to the pump that holds the return spring down onto the throttle level, was left loose during assembly. The bolt can work it self out, which would cause loss of throttle control and potentail overspeed.

AFFECTED PRODUCT

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Model	Identification Number
3406C	1SS01612-01616, 1620-1621, 1624-1626, 1628, 1635-1638, 1640-1642 4ZR08559-08560, 8564 6TB24356, 24363, 24371, 24460-24461, 24468-24469 PFH00711-00715, 717-718, 721-722, 724-725, 727, 729-731, 755, 757

PARTS NEEDED

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No parts needed for this program

ACTION REQUIRED

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

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NOTE: This is a 1.0-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 NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - Product Improvement Program For Inspecting And Torqueing The Governor Shaft Bolt

MODELS INVOLVED - Certain 3406 engines

Dear Caterpillar Product Owner:

A bolt, internal to the pump that holds the return spring down onto the throttle level, was left loose during assembly. The bolt can work it self out, which would cause loss of throttle control and potentail overspeed, which may result in personal injury or death. The part requires repair. 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 07Nov2006 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 07Nov2006 Service Letter

Rework Procedure

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Access to SISWEB references will be required as applicable: 1W1205, 4W7502, 1W1179, 1W1182, and 1295672.

1)Remove any accessories that will interfere or restrict the removal of the governor and actuator assembly. See illustration 1.1.1

Image1.1.1

2)Remove 2 Allen head retaining screws from the 8C6099 electric solenoid. Remove solenoid. (if applicable, not all models contain an electric shutoff solenoid)
3)Remove governor linkage by removing the 3D8752 Nut from the 1B1293 bolt. *Note the position & location of the 9M1974 washers for reinstallation in step #23 below if any washers are installed. Not all governor linkage requires washers. (If applicable).
4)Remove 2 retaining nuts & washers from the actuator. Remove the actuator assembly and oil drain line if applicable.
5)CAUTION - If the 6L3528 gasket is removed for any reason, note the position of the gasket opening for the oil passageway. If this gasket is installed backwards, all engine supplied oil is shutoff to the actuator assembly and the actuator will seize. See illustration 1.2.1 & 1.2.2.

Image1.2.1

Image1.2.2

6)Remove the 8N2148 actuator drive splined coupling from the 1W1205 housing by pulling it straight out.
7)Loosen & remove all ?? bolts which retain the 1W1205 governor housing to the fuel injection pump housing.
8)Pull / twist as need to remove 1W1205 governor housing assembly from the fuel injection pump. Caution, the 1W1205 housing is very heavy and contains residual engine oil. The 8N3238 gear assembly may fall out as the governor is removed. Replace the 8N3238 into the 1W1205 housing. Grease may be added between the gear and the housing to hold the gear in position for reassembly purposes.
9)Inspect and torque the 1N9882 governor shaft bolt to 12nm. See illustration 1.3.1.

Image1.3.1

10)Obtain a new 1W1186 gasket. Grease the gasket surface on the fuel injection pump and install the gasket over the pump housing dowels. The grease will assist to hold the gasket in place during the 1W1205 governor housing assembly process.
11)Remove 2 ? 4F7957 bolts from 1W5785 cover on the left (forward) side of the fuel injection pump.
12)Use a small pry bar to hold the 8N9367 rack in the full throttle position, in order to insert the 1W1191 lever (#13 below) (gently push to retain the rack toward the rear of the pump).
13)Begin the housing assembly process by inserting the 1W1191 lever into the 2N5920 rack extension. The rack extension slot must be perfectly vertical orientated to allow the 1W1191 to be inserted into it. (Caution, if for any reason the 2N5290 extension is removed from the rack, the internal 8H9186 spring must be reinstalled into the 2N5290 rack extension.
14)After the 1W1191 lever is hooked into the rack as in #13 above, remove the small pry bar from the front of the rack so the rack may move freely move.
15)Gently, rock & move the 1W1205 housing assembly from side to side until the stub shaft of the 8N3238 gear assembly inserts into the bushing in the fuel injection pump housing.
16)Install and torque all housing retaining bolts to 12nm.
17)Verify rack is connected to the governor throttle by moving the throttle lever forwards and backwards and note the rack movement by viewing the rack through the opening where the 1W5785 cover was removed. The rack is directly connected to the throttle arm and must move in both directions as directed by the governor arm movement. No free play is allowable.
18)Reinstall the 1W5785 pump side cover & torque the 2 - bolts to 12nm.
19) Move the throttle arm to full throttle position and press the 7L4984 manual shutoff lever forward to verify the MSO is functioning and therefore it is moving the governor arm forward toward the shutoff position.
20)Install 8N2148 actuator drive coupling onto the splines
21)Verify the 6L3528 gasket is in place as in #5 above.
22)Install the actuator by aligning the drive coupling?s splines. Slide actuator onto studs and install the washers & nuts. Torque to 25nm. Assemble oil drain tube if applicable.
23)Reconnect the actuator linkage to the governor arm and torque the bolt & nut to 12nm. *note the position of the 2 - 9M1974 washers as removed in step #3 above. (If applicable)
24)Manually move the governor lever forward and backwards and verify a free, smooth movement.
25)Reinstall the 8C6099 electric shut off solenoid by hooking the 4W7503 shaft over the 1W1187 lever inside the 1W1205 governor housing. Torque the screws to 12nm. (If applicable)
26)Manually move the governor shaft for movement. A wrench will be required to assist in moving the arm when an actuator is installed.
27)Reattach any accessories.