PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN DEFENSE AND FEDERAL PRODUCTS ENGINES Caterpillar


PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN DEFENSE AND FEDERAL PRODUCTS ENGINES

Usage:

REBE3855-01

29May2008
(Revised 03Jul2008)


U-285

 
Before/After
  
  

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN DEFENSE AND FEDERAL PRODUCTS ENGINES

1290 1251 1254 1713
PS42710
NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42710" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "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:

This Revised Service Letter replaces the 29May2008 Service Letter. Changes have been made to Affected Product and Action Required.


TERMINATION DATE

31May2010

PROBLEM

The spool spring that is internal to the 295-1410 Fuel Injector is failing prematurely on certain FMM and FML engines. Symptoms of this type of failure are consistent with a flutter, skipping, or a fuel knock from the engine at higher speeds. This type of failure is generally a low hour failure.
Note: Use the part hours that are on the fuel injector(s).

AFFECTED PRODUCT

Model Identification Number
DV-3126E FML04334-05512

FMM08554-11449, 11451-11458, 11460-11462, 11464-11466, 11468, 11470-11478, 11481-11488, 11490, 11492-11493, 11495-11496, 11498-11499, 11501-12034

PARTS NEEDED

Qty

Part Number Description
6 10R4763 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 27% 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

NOTE: Before a parts order can be placed to perform the rework outlined in this service letter, please call:

Todd Bong
Defense and Federal Products
Caterpillar Inc.
309-578-4288

Backup is:

Pat Bowen
Defense and Federal Products
Caterpillar Inc.
309-578-2351

Please have serial number of engines being repaired and number of injectors being needed before making call.

In order to manage the amount of parts on hand, priority of this rework will be managed by Caterpillar.


Take the following actions before or after a failure occurs on one or more injectors in any of the engines listed in this service letter.

- If one or more injectors fail it may be necessary to replace up to 6 injectors at the time of repair.

NOTE: There will be situations when all 6 injectors do not have to be replaced. Refer to next paragraph to determine which injectors should be replaced.

- If an injector repair has previously been performed after approximately 01Oct07 on any of the listed engines, only the injectors that were not replaced at that time should be replaced. This should further be verified by comparing the injector serial numbers in the engine to a range of 3B115776403B to 3B11676551F9. Disregard the first and last two characters in the serial number (in this case "3B" and "3B" in the first serial number and "3B" and "F9" in the second serial number). The reason for verifying the serial number range is due to a batch change of the internal part that is failing. The change was made after serial number 3B11676551F9.

NOTE: Only injectors falling within the range of 11577640-11676551 should be replaced.

- If the suspect injector can not be identified by using the automatic cylinder cutout test use the two methods below.

- First, run a manual cylinder cutout test at a high engine speed with some load on the engine. When the injector that has failed is cutout, the sound of the engine should be more normal as opposed to the loud knocking heard when the failed injector is active. The second method is to unplug the wiring harness at the valve cover base that sends current to the injector solenoids as well as the harness connection for the injection actuation pressure sensor. By making these disconnections, the fuel injectors will not fire and the HEUI pump will go to maximum actuation pressure. Then remove the valve cover and crank the engine. The injectors that have failed should expel more oil (from the HEUI System) than those that are not failed.

-Refer to RENR9579 for removal/install procedure of the unit injector.

-The serial number of all injectors replaced in an engine covered under this service letter must be documented in the claims story.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-1000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 4.0-hour job
The serial number of any injector(s) replaced in an engine covered under this service letter must be documented in the claims story. Only injectors with serial numbers between 11577640-11676551 (see action required for explanation on how to decode injector serial number) will be allowed to be claimed under this service letter.

NOTE: If there has been a previous repair, part age will apply. Retain a copy of the previous repair in the dealer's records for audit purposes, and specify repair date and engine hours in the "Additional Comments" section of the warranty claim.



PARTS DISPOSITION

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

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