PRODUCT IMPROVEMENT PROGRAM TO INSPECT AND POSSIBLY REPLACE THE NRS COOLERS AND REPLACING THE OUTLET CHECK VALVES OF THE COMMON RAIL FUEL PUMP ON CERTAIN C9.3 INDUSTRIAL ENGINES

PRODUCT IMPROVEMENT PROGRAM TO INSPECT AND POSSIBLY REPLACE THE NRS COOLERS AND REPLACING THE OUTLET CHECK VALVES OF THE COMMON RAIL FUEL PUMP ON CERTAIN C9.3 INDUSTRIAL ENGINES - MULTIPLE REPAIRS

Usage:

REBE7822-00

Show/hide table

19Dec2011

U-566

O-498

Show/hide table

*Priority*	PRODUCT IMPROVEMENT PROGRAM TO INSPECT AND POSSIBLY REPLACE THE NRS COOLERS AND REPLACING THE OUTLET CHECK VALVES OF THE COMMON RAIL FUEL PUMP ON CERTAIN C9.3 INDUSTRIAL ENGINES - MULTIPLE REPAIRS
1251		PI31962

Show/hide table

NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI31962" 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 "PI31962" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

COMPLETION DATE	TERMINATION DATE
30Jun2012	31Dec2012

PROBLEM

Show/hide table

The exhaust manifold on the C9.3 Industrial Engines listed may contain metallic debris that can eventually fail the cooler, causing coolant to enter the engine. This debris is introduced from the exhaust manifold and was not properly cleaned out during the manufacturing process. Also, the outlet check valves on the common rail fuel pump also need replaced. The current outlet check valves can wear prematurely causing E499 diagnostic code and engine derate.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
C9.3	C9N00178-00181, 500-503, 505-525, 527, 529-530, 534-539

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
2	9N5085	CLAMP-V-BAND
2	3147599	CLAMP-BAND - IF NEEDED
1	3249290	BELLOWS AS
1	3457645	COOLER GP-EXH -B - IF NEEDED
1	3808558	HOSE - IF NEEDED
1	3841555	KIT-OUTLET VALVE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 33% 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

Show/hide table

Refer to attached Rework Procedure.

Make every effort to complete this program prior to the machine reaching 200 hours. Analysis has shown that is a failure is going to occur, it will occur prior to 200 hours.

Note: A Customer Notification Letter will not be sent out with this program.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

Show/hide table

NOTE: This is a 1.5-hour job
An additional 8 hrs will be allowed for NRS cooler replacement if debris is found in the cooler. If debris found and the NRS cooler is replaced, please provide photos of the old NRS cooler showing the debris in the claims story.

Show/hide table

PARTS DISPOSITION

Show/hide table

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

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

Rework Procedure

Show/hide table

NRS Cooler Inspection

1. Record the exhaust manifold machining code from the flange on the exhaust manifold connection at the cylinder 1 exhaust port. Refer to Image1.2.1 and Image1.2.2 for the exact location of the machining code. It may be necessary to use scotch brite to clean rust away from code location. After scrubbing with scotch brite, use a wet cloth and wipe the area. This can bring out the code for better visibility. This can be done without moving any components. Use of a telescoping mirror and flashlight should allow for viewing of the code.

Note: Some codes may be unreadable due to paint or other issues.

Image1.2.1

Image1.2.2

2. Remove any brackets or shielding that may inhibit access to the NRS cooler bellows.

3. Remove clamps connecting the bellows to the exhaust manifold and the NRS cooler. Soak clamps in penetrating oil prior to removal in order to assist in removal. Refer to Image1.4.1.

Image1.4.1

4. Using 361-5661 Bellows Tool Assembly, remove the bellows from the engines. Refer to Image1.5.1 and Image1.5.2.

Image1.5.1

Image1.5.2

5. Inspect the face of the NRS cooler. Use a flashlight and a magnet to complete a thorough inspection. Image1.6.1 and Image1.6.2 provide examples of debris. If debris is found, leave in the NRS cooler and take a picture of location. This image must be attached to claim in SIMSi.

Image1.6.1

Image1.6.2

6. If debris is found, replace the NRS cooler. Refer to the Disassembly and Assembly manual for the proper procedure.

7. If debris is not found, install new 324-9290 Bellows Assembly using new 9N-5085 Clamps. Tighten the clamps to 7.5 N.m.

Note: The bellow assemblies must be installed in the proper direction. Refer to Image1.8.1.

Image1.8.1

COMMON RAIL FUEL PUMP CHECK VALVE REPLACEMENT

1. If machine has any active or logged E398, E499 or E1220 event codes, perform the proper troubleshooting outlined in the troubleshooting guide for the product being serviced. If the machine has no active or logged E398, E499 or E1220 event codes, proceed to Step 2.

2. Thoroughly clean around the outlet check valve plugs. Use a wire brush in order to remove excessive paint from the plugs. Follow this step with the use of cleaning solution such as brake cleaner or contact cleaner. Check the plugs that are circled in Image1.11.1.

Image1.11.1

3. Remove the check valve plugs. Use a magnetic bolt tray to hold underneath the check valve plugs during removal. This will ensure that any piece parts are not dropped. If the check valve does not come out with plug, use a magnet in order to remove the check valve from the bore. Refer to Image1.12.1.

Image1.12.1

4. Use a Q-tip and soak with alcohol or contact cleaner. Swab the threads and the bore that the check valve was removed from in order to clean any debris.

5. The old check valve will not be reused. Clean both new check valves from the 384-1555 Outlet Kit with brake cleaner or contact cleaner. Load the spring into the check plug. Apply lithium grease to the end of the spring. Refer to Image1.14.1. Take note of the spring height when installed in plug. If the ball stud has fallen out, the spring will sit lower. The spring should be at a height similar to letter A in Image1.14.2.

Image1.14.1

Image1.14.2

6. Insert the new check valve into the bore in fuel pump.

NOTE: Ensure that the check valve does not slide out of the bore before re-installing the plug.

7. Carefully thread the plug into the fuel pump. Thread the plug in by hand. Tighten the plug to 75 N.m +/- 5 N.m.

8. Repeat Step 1 through Step 7 for the second check valve replacement.

9. Start engine and warm up. Make sure engine is running properly and no leaks are present. If engine is running good and no fault codes are present, rework is complete. If any fault codes become active, follow the engine troubleshooting guide for the product being serviced.