PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN 330D HYDRAULIC EXCAVATORS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN 330D HYDRAULIC EXCAVATORS [REBE3818]

FUEL SYSTEM

PUMP GP-FUEL INJECTION

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN 330D HYDRAULIC EXCAVATORS

REBE3818-02

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28May2008

(Revised 20Mar2009)

U-280

A-228

D-226

O-249

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN 330D HYDRAULIC EXCAVATORS
1290 1251 1254 1713		PS42708

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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 "PS42708" 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.

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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 AVSpare product analyst.

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NOTE:	This Revised Service Letter replaces the 28May2008 (Revised 02Jul2008) Service Letter. Changes have been made to Termination Date.

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TERMINATION DATE

31Mar2009

PROBLEM

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The spool spring that is internal to the 293-4072 and 293-4073 Fuel Injectors is failing prematurely on certain 330D Hydraulic Excavators. 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

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Model	Identification Number
*****Group 1*****
330D	EAH00517, 536, 538-539, 549-550, 561, 581, 592-828 ERN00304-00335 FFK00262-00376 GGE00594-00743 JJM00222 LCJ00209-00224 MEY00347-00361 NBD00977-01054 PFC00155-00170 RAS00806-01002 THJ00292, 295-316
330D FM	L2K00223-00226
330D FM HEEL	H3K00359-00364
330D L	B6H00595-00651 JLP00381-00548 LRM00251-00344 MWP01680-02117 RDK00155-00156 T2Y00389-00407
330D MH	PEL00171-00174
330D MH FCR	LEM00201-00208

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*****Group 2*****
330D L OEM	H3D00200-00248
330D LN OEM	GMN00101
330D OEM	D3D00152, 162, 164, 221-305

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	10R7222	INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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.
*****Group 2*****
6	10R7223	INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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

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Take the following actions before or after a failure occurs on one or more injectors in any of the machines 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 machines, 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 a machine covered under this service letter must be documented in the claims story.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
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 for Group 1
The serial number of any injector(s) replaced in a machine 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 machine hours in the "Additional Comments" section of the warranty claim.

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Product smu/age whichever comes first	AVSpare		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
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 for Group 2
The serial number of any injector(s) replaced in a machine 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 machine hours in the "Additional Comments" section of the warranty claim.