09010-05240 BODY ASSY, INJECTI Denso Cross

April 3, 2006
U-101
O-88
Priority PRODUCT IMPROVEMENT PROGRAM FOR REPLACINGTHE INJECTION PUMP ON CERTAIN 3412C GENERATOR SETS
1251 PI30918
This Program must be administered assoon as possible. When reporting the repair, use "PI30918" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI30918" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.
COMPLETION DATE
TERMINATION DATE
October 31, 2006 April 30, 2007PROBLEM
The rack bar 4P-7326 has a slot machined in itthat is not to print. The slot is too narrow. This causes the bar insertedin the slot to bind up and impair the rack movement. We have traced therack bars from the twenty-three sticky rack failures and they all fallinto two Woodward manufacturing lots. The 168 injection pumps built withthe two suspect rack bar lots are in the serial range from 14415965 to14446549.FG Wilson, with an injection pump in the suspectserial number range. Suspect injection pumps will be returned to Woodwardfor rework. Engines in the field will be handled in an alternative manner.Unfortunately, it is not acceptable to change the injection pump and notre-dyno test the engine. The plan is to remove and replace the injectionpump on any engine or generator-set in house, including engine.AFFECTED PRODUCT
Model IdentificationNumber
3412C DJN758-762,790, 796-797, 802-805, 807, 809-811, 813, 815, 820-821TFT441PARTS NEEDED
Qty
Part Number Description
* 6I-2358 Injection Pump* Order only if needed after the inspectionhas been completed.ACTION REQUIRED
See the attached Rework Procedure.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
100% 6.5 0 0 0 0
Thisis a 5.0 hr job for the pump relplacement. An additonal 1 hr segment willalso be added to the labor hours to account for dyno testing an enginethat has had the fuel injection pump replaced.* An additional 0.5 hrs will beallowed for inspection per engine. PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked with the service letter number.***** All Dealers *****Return all defective 6I-2358 injection pumpsremoved from engines. Also send in a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery
Service Claims Room
8201 N. University
Peoria, IL 61615MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (1-Owner Notification)
(2-Rework Procedure)COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999PRIORITY - PRODUCT IMPROVEMENT PROGRAM FORREPLACING THE INJECTION PUMPMODELS INVOLVED - CERTAIN 3412C GENERATOR SETSDear Caterpillar Product Owner:The injection pump needs to be inspected andpossibly replaced on the products listed below. You will not be chargedfor the service performed.Contact your local Caterpillar dealer immediatelyto schedule this service. The dealer will advise you of the time requiredto complete this service. Please refer the dealer to their Service Letterdated April 3, 2006 when scheduling this service.We regret the inconvenience this may causeyou, but urge you to have this service performed