PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN C7 POWERED MACHINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN C7 POWERED MACHINES [REBE3824]

FUEL SYSTEM

PUMP GP-FUEL INJECTION

PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN C7 POWERED MACHINES

REBE3824-02

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29May2008

(Revised 20Mar2009)

U-284

A-231

D-227

O-251

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN C7 POWERED MACHINES
1290 1251 1254 1713		PS42709

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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 "PS42709" 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 29May200 (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 295-1411 Fuel Injector is failing prematurely in the C7 Engine on the various machines identified in this service letter. 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
140M	B9D00133-00621, 623, 626-646, 648, 650, 653-654, 656-662, 664-665, 668-673, 676-678, 682-687, 694-695, 697-699, 702-703, 706-707, 711-712, 714-716, 719-722, 724-725, 732, 734-736, 741-743, 745-748, 751-758, 761-762, 764, 766-787, 789, 792-793, 796, 805, 810, 815, 826, 828, 841-844, 846, 863-864, 870-871 B9M00144-00242, 247, 249-250, 252-253, 255, 261, 269-270
324D	CJX00245-00302
324D L	DFP00320-00337 JJG00511-00735 SYM00592-00679 T2D00299-00344
324D LN	EJC00627-00722 LAB00411-00414
324D OEM	KJR00135-00146
325D	CJM00173-00178 DBH00105-00430 GPB00758-00931 KDG00203-00209 PEH00229-00230 PKE00783-00968 SCR00732-00771
325D FM	C7K00207-00208
325D FM BUTT N	C9M00143-00144
325D FM HEEL	C8L00172-00177
325D L	A3R00785-00928 MCL00199-00210
325D OEM	C3N00100-00153, 155-357
328D	GTN00250-00308 MKR00204-00207
525C	52500471-00540
535C	53500281-00292
545C	54500390-00397
950H	J5J00471-00597 K5K01426-01754 M1G00910-01168 N1A01638-01900, 1944-1966
962H	J6J00221-00250 K6K00296-00337 M3G00310-00374 N4A00622-00773
AP-1000D	EAD00209-00245
AP-1055D	A6P00115-00119 FAC00501-00532, 534-542
BG-2455D	BNW00123-00125
BG-260D	BPW00122-00129
C7 OEM	F7N00136-00138, 140-159
IT62H	M5G00329-00364
M325D L MH	KAY00253-00256 KGG00240-00245
M325D MH	EDF00268-00274

PARTS NEEDED

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Qty	Part Number	Description
6	10R7225	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%
0-1000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 4.0-hour job
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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