PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE FUEL INJECTION PUMP ON CERTAIN TURBOCHARGED 414E, 416E, 420E, AND 430E BACKHOE LOADERS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE FUEL INJECTION PUMP ON CERTAIN TURBOCHARGED 414E, 416E, 420E, AND 430E BACKHOE LOADERS [REBE3593]

FUEL SYSTEM

PUMP GP-FUEL INJECTION

PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE FUEL INJECTION PUMP ON CERTAIN TURBOCHARGED 414E, 416E, 420E, AND 430E BACKHOE LOADERS

REBE3593-01

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08May2008

(Revised 14May2008)

U-241

A-196

D-191

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE FUEL INJECTION PUMP ON CERTAIN TURBOCHARGED 414E, 416E, 420E, AND 430E BACKHOE LOADERS
1251		PI10683

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10683" 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 "PI10683" 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 08May2008 Service Letter. Changes have been made to a seal part number within the Rework Procedure.

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PROBLEM

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The fuel injection pump needs to be inspected and possibly replaced on certain 3054C turbocharged engines installed in certain E-Series backhoe loaders. The existing fuel injection pump can cause an increase in engine speed that may result in personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
414E	ELB00726, 729-730, 738, 750, 752, 756-757, 763-782, 784-787, 789-797
416E	CBD02484-02486, 2498-2499, 2552-2554, 2562-2564, 2567-2576, 2578, 2582, 2589, 2594, 2596, 2615-2617, 2620, 2626-2631, 2635-2636, 2643, 2646-2650, 2654, 2663, 2692, 2698, 2700-2701, 2704-2706, 2710, 2712, 2714, 2717, 2724, 2735-2736, 2747, 2753, 2755-2756, 2759, 2765, 2775, 2843, 2847-2848, 2904-2907, 2910-2919, 2921-2923, 2932-2933, 2946-2948, 2956-2958, 2962-2963, 2998-3000, 3005-3006, 3008, 3029-3030, 3037, 3040, 3042-3044, 3050 SHA03976, 3978-3983, 3986-3987, 4001, 4003, 4005-4013, 4015, 4017-4026, 4028-4029, 4031, 4033, 4035-4036, 4043, 4051-4054, 4056-4058, 4061, 4064, 4068-4071, 4074-4077, 4081, 4087, 4091-4096, 4099, 4101-4108, 4110-4124, 4126-4130, 4132-4133, 4135-4142, 4144, 4146, 4149-4151, 4155, 4168-4170, 4174, 4178-4193, 4195, 4201, 4203, 4207-4208, 4210, 4212-4219, 4221, 4224-4226, 4233-4240, 4243, 4250, 4252, 4254-4255, 4262, 4264-4267, 4269, 4271-4279, 4283-4293, 4295-4299, 4302-4312, 4314-4315, 4317-4322, 4324-4330, 4332-4341, 4343-4348, 4350-4354, 4356-4366, 4370, 4372-4374, 4376-4378, 4381-4392, 4394, 4397-4402, 4410-4416, 4418-4421, 4423-4432, 4434-4444, 4446-4447, 4449, 4451-4454, 4456-4466, 4468-4477, 4479-4482, 4484, 4486-4489, 4492-4494, 4497-4498, 4501-4505, 4508-4509, 4511, 4515, 4517, 4528, 4530-4532, 4534, 4536, 4539-4542, 4544-4547, 4549-4550, 4552-4555, 4557-4559, 4561-4566, 4569-4590, 4592-4616, 4618, 4621-4624, 4626-4628, 4630, 4635-4640, 4646-4648, 4654, 4656-4658, 4668-4669, 4677-4678, 4680-4685, 4687, 4693-4694, 4696-4697, 4700, 4705, 4707-4709
420E	HLS05953-05959, 5961-5981, 6006-6061, 6063-6070, 6072-6173, 6194-6213, 6215-6273, 6275-6324, 6326-6330, 6332-6393, 6395-6528, 6532, 6534-6560, 6562-6588, 6590-6685, 6687, 6689-6693, 6695-6697, 6700-6703, 6705-6714, 6718, 6720-6723, 6725-6729, 6731-6735, 6737-6741, 6743-6753, 6755, 6759-6761, 6765-6767, 6771, 6775-6777, 6779-6780, 6784, 6792, 6827-6828, 6842, 6853 KMW02304-02312, 2323-2393, 2395, 2398, 2413-2432, 2434-2522, 2525, 2527-2529, 2531-2539, 2541, 2543-2568, 2570-2575, 2577-2579, 2581-2589, 2592-2593, 2596-2597, 2599-2601, 2603, 2605-2607, 2610-2611, 2613, 2616-2618, 2622, 2629-2631, 2634, 2637, 2644, 2646, 2648, 2655

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*****Group 2*****
430E	DDT00730-00743, 749-751, 753-761, 763-774, 776-777, 780-782, 784 EAT01115-01117, 1122-1142, 1145-1147, 1150, 1152-1173, 1176-1177, 1179-1183, 1185-1186, 1188, 1190-1194, 1196-1197, 1208, 1223

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	2744962	PUMP GP-F INJ (As required per rework procedure)
The pump on the machine needs to be inspected according to the attached Rework Procedure. Only order a new pump if the pump fails the inspection procedure.
*****Group 2*****
1	2482356	PUMP GP-F INJ (As required per rework procedure)
The pump on the machine needs to be inspected according to the attached Rework Procedure. Only order a new pump if the pump fails the inspection procedure.

ACTION REQUIRED

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Check the fuel pump identification plate to determine that the pump is contained within the range to be inspected, perform detailed inspection, determine if pump replacement is necessary, and replace fuel pump as required. Refer to attached Rework Procedure.

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OWNER NOTIFIAVSION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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AVSpare		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 1.5-hour job for Group 1
1) An additional allowance of 4.0 hours can be claimed if the pump needs to be replaced after failing inspection. 2) Should the Dealer not have access to a Bore Scope an allowance of $250 per Dealer is allowed for the purchase of this tool.

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AVSpare		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 1.5-hour job for Group 2
1) An additional allowance of 4.0 hours can be claimed if the pump needs to be replaced after failing inspection. 2) Should the Dealer not have access to a Bore Scope an allowance of $250 per Dealer is allowed for the purchase of this tool.

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PARTS DISPOSITION

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

For NACD

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AVSpare Inc.

Attn: Supplier Recovery

Service Claims Room

8201 N. University

Peoria, IL 61615

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

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COPY OF OWNER NOTIFIAVSION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE FUEL INJECTION PUMP ON CERTAIN TURBOCHARGED 414E, 416E, 420E, AND 430E BACKHOE LOADERS

MODELS INVOLVED - 414E, 416E, 420E, 430E

Dear AVSpare Product Owner:

The Fuel Injection Pump needs to be inspected and possibly replaced on the products listed below. The existing Fuel Injection Pump can cause an unexpected increase in engine speed which may result in personal injury or death.

You will not be charged for the service performed.

Contact your local AVSpare 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 08May2008 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.

AVSpare Inc.

Identification #(s)

Attached to 08May2008 Service Letter

Rework Procedure

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Tools required for the inspection of the fuel injection pump are:
17 mm hexagonal socket 3/8" drive.
3/8" drive ratchet wrench with 300 mm extension
Bore Scope with flexible end and ninety degree viewing lens. The Bore Scope has to be capable of being inserted in a 10 mm diameter hole. A 6 mm Bore Scope is recommended for optimium viewing.

1) Before proceeding, first check the serial number shown on the pump identification plate. Image 1.1.1

Image1.1.1

If the machine is identified in the Affected Product and the fuel pump serial number ends with the letter "B" as indicated in image 1.1.1 then the fuel pump should be further inspected.

2) Remove engine compartment door by removing the three bolts holding the door in place using a 13 mm ratchet and socket. Pull the rear of the door away from the machine and then pull the door towards the rear of the machine to remove it from the radiator guard. Image 1.2.1

Image1.2.1

3) Record pump and engine serial number.

NOTE: Only carry out the following procedure if the pump type number is identified with the "B". (The pumps without the "B" are not affected by this problem).

4) Ensure the area around the fuel return connection is clean. The connection is on the top of the fuel pump toward the front of the engine. Image 1.3.1

Image1.3.1

5) Use a 17 mm X 3/8" drive hexagonal socket, extension 3/8" x 3/8" x 300 mm length and ratchet wrench 3/8" drive to release and remove the return connection fitting.

Note: Be careful not to damage the fitting and o-rings (image 1.4.1), and ensure nothing is allowed into the return connection hole indicated by the arrow. To view the fuel pump mechanism insert a bore scope into the fuel return connection hole as shown in the image.

Image1.4.1

6a) Using the bore scope verify if the nut and lock nut are in the correct position. See image 1.5.1. for the correct position of the locknut showing a number of threads extending beyond the lock nut postion. Image 1.5.2. shows the lock nut in the incorrect positon close to the end of the threads.

Draining fuel or removing fuel from the pump by siphoning through the inspection aperture can improve viewing of the nut and lock nut.

Remove the bore scope from the hole and refit the return connection. NOTE: If the O - ring is damaged during this operation it will require replacing. Your local Delphi agent should be contacted for replacements. Delphi part number 7185-950DV

Tighten the connection to a torque of 25 Nm.

6b) In addition to the visual check, start the engine and ensure that the no load engine speed is not greater then 2350 rpm. If the speed is found to be in excess of 2350 then the engine is to be shut down immediately. It is recommended that for the speed check a Phototach infrared tachomemter or similarly accurate speed measurement device is used to check engine speed.

If the pump does not comply with the recommendations in 6a) and 6b) then remove pump and refit a new pump in accordance with Disassembly & Assembly instructions for the 3054C Engine (SENR5069).

Image1.5.1

Image1.5.2

7)Record that the machine has been inspected.

8) Once inspection and refitting of connection is complete run the engine to ensure that the fuel pump is leak free.

9) Refit panels previously removed.