PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP ON CERTAIN C9 MARINE AUXILIARY AND GENERATOR SET ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP ON CERTAIN C9 MARINE AUXILIARY AND GENERATOR SET ENGINES

Usage:

REBE8022-01

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03May2012

(Revised 15Aug2012)

U-244

A-195

D-207

O-222

TM-3

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*Before/After*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP ON CERTAIN C9 MARINE AUXILIARY AND GENERATOR SET ENGINES
1714		PS43590

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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 "PS43590" 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 Caterpillar product analyst.

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NOTE:	This Revised Service Letter replaces the 03May2012 Service Letter. Changes have been made to the Affected Product, Parts Needed, Action Required, and Service Claim Allowances.

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TERMINATION DATE

31May2014

PROBLEM

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The existing HEUI pump can have a bearing failure. When this bearing fails, metal pieces from the bearing can enter the HEUI pump control valve and the passages leading to the injectors. When the control valve and/or injectors have this metal contamination, the engine may not start or may exhibit unstable operation.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C9	C9A00151-00155, 157-160, 163, 167-173, 175-177, 181-185, 187-196, 200, 202, 204, 209-211, 215, 217-218, 223, 226, 236-237, 245, 258, 261, 263-264, 266, 270, 272, 275-277, 279, 281-284, 287-288, 294-295, 298, 304, 307, 310, 320-321, 339, 342-343, 360-361, 370-373, 395, 397-414, 416, 418-448, 451-454, 456-457, 462-470, 473-493, 499-500, 505-540, 545-548, 550-552, 554-565, 567-571, 579, 589-595, 598-600, 602-621, 626-627, 632-634, 639-643, 646-660, 663-664, 668-671, 673, 675, 678-692, 694-722, 725-737, 742-743, 747-785, 787-791, 797, 799-809, 811-812, 816-817, 822-833, 835-898, 900-904, 907, 909-910, 913-916, 918-925, 927-935, 940-958, 962-989 C9Y00150-00251 SJB00159, 167, 169, 173, 179-185, 187, 189, 194, 197-198, 212, 225, 234, 243-244, 247, 252-254, 257, 264-266, 276, 281-282, 284-290, 293-294, 296-297, 300, 302-308, 310-316, 318-320, 322-323, 326, 329-333, 335-346, 348-350, 352-360, 362, 364, 366-368, 372-374, 376, 378-388, 390-393, 399, 404-409, 411-432, 434-436, 438-440, 443, 445-450, 453-460, 468, 471-473, 475-476, 480, 484-486, 490, 492-498, 500-508, 510-513, 515, 518-531, 535-538, 542-543, 547-549, 551-554, 559-563, 567-572, 574, 582-585, 591-595, 597-598, 602, 604, 607, 609, 614-617, 619-620, 623-624, 627-632, 634, 649-651, 653-660, 669-675, 677-678, 681, 683-687, 690, 693-701, 703, 708-710, 712, 714, 717-721, 723-729, 732-736, 738, 741-752, 754-757, 759-761, 763, 765-766, 768-769, 771, 774, 776-777, 779, 783, 785-788, 792, 797-807, 809, 811-818, 821-822, 825-826, 828-829, 831-832, 838, 841, 843, 846-847, 852, 854-858, 861, 864-871, 873, 875-902, 904-905, 908-909, 911-914, 917-923, 925-929, 931-934, 936, 940-945, 947, 949-952, 955-958, 961-979, 981-985, 988-1001, 1003-1016, 1020-1021, 1023-1030

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*****Group 2*****
C9	SJB00488, 491, 661, 665, 676

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*******Group 3*******

C9Y00252-00383

SJB00444, 464, 469, 477, 482, 499, 509, 514, 516-517, 532-534, 540-541, 550, 564-565, 581, 596, 599, 601, 603, 606, 608, 611-612, 618, 621-622, 642, 648, 662-663, 667-668, 679-680, 688, 704-707, 713, 715, 722, 730, 739-740, 762, 764, 767, 770, 780-782, 784, 808, 810, 819, 823, 827, 830, 844-845, 850, 859-860, 862-863, 872, 874, 903, 906-907, 910, 915-916, 924, 930, 935, 948, 953-954, 959-960, 980, 986-987, 1002, 1017-1019, 1022, 1031-1138, 1141-1184, 1186-1199, 1202

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*******Group 4*******

C9A00164-00165, 212-214, 219-221, 233-235, 257, 268, 278, 280, 311-317, 322, 325-327, 330, 338, 345-348, 350, 364-367, 374-376, 378, 383-386, 388, 396, 415, 417, 449-450, 455, 458-461, 471-472, 494-498, 501-504, 549, 553, 566, 572-578, 580-588, 596-597, 601, 622-623, 628-631, 635-636, 661-662, 666-667, 672, 693, 723-724, 738-741, 744-745, 792-796, 810, 813-815, 818-821, 834, 899, 905-906, 908, 911-912, 917, 926, 936-939

SJB00150-00158, 160-166, 168, 170-172, 174-178, 186, 188, 190-193, 195-196, 199-209, 211, 213-224, 226-233, 235-242, 245-246, 248-251, 255-256, 258-263, 267, 269-275, 277-280, 283, 291-292, 295, 299, 301, 309, 317, 321, 324-325, 327-328, 334, 347, 351, 361, 363, 365, 369-371, 375, 377, 389, 394-398, 400-403, 433, 437, 441-442, 451-452, 461-463, 465-467, 470, 474, 478-479, 481, 483, 487, 489, 539, 544-546, 555-557, 566, 573, 575-580, 586-590, 600, 605, 610, 613, 625-626, 633, 635-641, 643-645, 647, 652, 664, 666, 682, 689, 691-692, 702, 711, 716, 731, 737, 753, 758, 772, 775, 778, 789-791, 793-796, 820, 824, 836-837, 839-840, 842, 848-849, 851, 853

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*****Group 5*****
C9	C9A00156, 162, 166, 174, 178-180, 186, 197-199, 201, 203, 205-208, 216, 224-225, 227-232, 238-244, 246-256, 259-260, 262, 265, 267, 269, 271, 273-274, 289-293, 296-297, 305-306, 308-309, 318-319, 323, 328-329, 332-337, 340-341, 349, 351-353, 355-356, 362-363, 368-369, 377, 379-382, 387, 389-394

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*****Group 6*****
C9	C9A00299-00303, 324, 331, 344

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	1R1808	FILTER-LUBE (After Failure Only)
2	4F8824	SEAL-O-RING
2	4P3871	GASKET
2	5K5959	SEAL-O-RING
1	9F4446	SEAL-O-RING
1	9S8003	PLUG-LD STOR (As Required)
6	10R2828	INJECTOR GP-FUEL (After Failure Only)
1	20R1636	PUMP GP -B
1	1949569	GASKET
2	1949570	GASKET
1	2053079	ADAPTER-STR (As Required)
2	2147567	SEAL-O-RING-STOR
11	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
6	2287089	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3788430	TUBE AS
1	3879500	TUBE AS
1	OIL_BULK	27.5 L Bulk Oil (After Failure Only)
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*****
1	1R1808	FILTER-LUBE (After Failure Only)
1	9F4446	SEAL-O-RING
1	9S8003	PLUG-LD STOR (As Required)
6	10R2828	INJECTOR GP-FUEL (After Failure Only)
1	20R1636	PUMP GP -B
1	2053079	ADAPTER-STR (As Required)
2	2147567	SEAL-O-RING-STOR
11	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
4	2287089	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3877159	TUBE AS-OIL
1	3879500	TUBE AS
1	OIL_BULK	27.5 L Bulk Oil (After Failure Only)
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 3*****
1	1R1808	FILTER-LUBE (After Failure Only)
1	9F4446	SEAL-O-RING
1	9S8003	PLUG-LD STOR (As Required)
6	10R2828	INJECTOR GP-FUEL (After Failure Only)
1	20R1636	PUMP GP -B
1	2053079	ADAPTER-STR (As Required)
2	2147567	SEAL-O-RING-STOR
11	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
6	2287089	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3788430	TUBE AS
1	3879500	TUBE AS
1	OIL_BULK	27.5 L Bulk Oil (After Failure Only)
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 4*****
1	1R1808	FILTER-LUBE (After Failure Only)
2	4F8824	SEAL-O-RING
2	4P3871	GASKET
2	5K5959	SEAL-O-RING
1	9F4446	SEAL-O-RING
1	9S8003	PLUG-LD STOR (As Required)
6	10R2828	INJECTOR GP-FUEL (After Failure Only)
1	20R1636	PUMP GP -B
1	1949569	GASKET
2	1949570	GASKET
1	2053079	ADAPTER-STR (As Required)
2	2147567	SEAL-O-RING-STOR
11	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
4	2287089	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3877159	TUBE AS-OIL
1	3879500	TUBE AS
1	OIL_BULK	27.5 L Bulk Oil (After Failure Only)
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 5*****
1	1R1808	FILTER-LUBE (After Failure Only)
2	4F8824	SEAL-O-RING
2	4P3871	GASKET
2	5K5959	SEAL-O-RING
1	6V8724	ADAPTER-ELBOW 90
1	9F4446	SEAL-O-RING
1	9S8003	PLUG-LD STOR (As Required)
6	10R2828	INJECTOR GP-FUEL (After Failure Only)
1	20R1636	PUMP GP -B
1	1949569	GASKET
2	1949570	GASKET
1	2053079	ADAPTER-STR (As Required)
2	2147567	SEAL-O-RING-STOR
12	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
7	2287089	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3391587	HOSE AS
1	3788430	TUBE AS
1	3879500	TUBE AS
1	OIL_BULK	27.5 L Bulk Oil (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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 6*****
1	1R1808	FILTER-LUBE (After Failure Only)
2	4F8824	SEAL-O-RING
2	4P3871	GASKET
2	5K5959	SEAL-O-RING
1	6V8724	ADAPTER-ELBOW 90
1	9F4446	SEAL-O-RING
1	9S8003	PLUG-LD STOR (As Required)
6	10R2828	INJECTOR GP-FUEL (After Failure Only)
1	20R1636	PUMP GP -B
1	1949569	GASKET
2	1949570	GASKET
1	2053079	ADAPTER-STR (As Required)
2	2147567	SEAL-O-RING-STOR
12	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
5	2287089	SEAL-O-RING-ORFS
2	2287096	SEAL-O-RING-STOR
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3391587	HOSE AS
1	3877159	TUBE AS-OIL
1	3879500	TUBE AS
1	OIL_BULK	27.5 L Bulk Oil (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 15% 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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Group 1 is dual wall 242-7032 Lines Group and rectangular 242-5336 Aftercooler.

Group 2 is single wall 242-7031 Lines Group and radiator cooling.

Group 3 is dual wall 242-7032 Lines Group and either the cylindrical 303-8551 Aftercooler or radiator cooling.

Group 4 is single wall 242-7031 Lines group and rectangular 242-5336 Aftercooler.

Group 5 is dual wall 242-7032 Lines group and rectangular 242-5336 Aftercooler and 192-2184 fuel tube.

Group 6 is single wall 242-7031 Lines group and rectangular 242-5336 Aftercooler and 192-2184 fuel tube.

1) Perform a cylinder cutout test to identify any inoperable injectors.

2) Groups 1, 4, 5, 6. Drain and remove the aftercooler. Retain the coolant for re-installation if keel cooled.

3) Perform Steps 4, 5 and 6 of REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)".

4) Inspect the coil for debris as described in Step 7 of REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)". If debris was found and/or an injector was found inoperable in Step 1, perform REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)". Ensure the system is flushed through six injector bores, two large end plugs and six small plugs.

5) If engine was built before January 2006 and the cylinder head has not been replaced, the HEUI pressure sensor may need to be relocated due to interference with the large diameter oil line. See Image1 for details on the relocation.

6) Transfer fittings and plugs from old pump to new pump and install. Ensure to finger tighten all line connections before final torque. Tighten the high pressure line connections to 45 Nm. Utilize 242-7032 Oil Lines Group drawing, Image2, and 388-2124 Mounting And Pump Group drawing, Image3, and Image4 for component locations and torque sequences. Wrap connections with SOLAS tape if necessary.

7) Groups 5 and 6. Remove 192-2184 fuel tube and install 339-1587 hose using Image5 for reference.

8) Groups 1, 4, 5, 6. Reinstall aftercooler using anaerobic sealant where necessary.

9) Prime fuel system using priming pump until fuel pressure is achieved. Disconnect injector harness and crank engine until oil pressure is achieved. Do not crank more than 30 seconds, providing a starter cool down period if necessary.

10) Check the oil level and fill if necessary.

11) Start engine and check for leaks.

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Image1

Image2

Image3

Image4

Image5

SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 1*****
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 1
After failure can claim additional 3.0 hour for performing Oil Rail Cleaning Procedure. There is a $100 miscellaneous allowance for purchase of SOLAS tape (if required by Marine Classification Society). Travel and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 2*****
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 2
After failure can claim additional 3.0 hour for performing Oil Rail Cleaning Procedure. There is a $100 miscellaneous allowance for purchase of SOLAS tape (if required by Marine Classification Society). Travel and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 3*****
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 2.0-hour job for Group 3
After failure can claim additional 3.0 hour for performing Oil Rail Cleaning Procedure. There is a $100 miscellaneous allowance for purchase of SOLAS tape (if required by Marine Classification Society). Travel and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 4*****
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 4
After failure can claim additional 3.0 hour for performing Oil Rail Cleaning Procedure. There is a $100 miscellaneous allowance for purchase of SOLAS tape (if required by Marine Classification Society). Travel and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 5*****
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 5
After failure can claim additional 3.0 hour for performing Oil Rail Cleaning Procedure. There is a $100 miscellaneous allowance for purchase of SOLAS tape (if required by Marine Classification Society). Travel and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
*****Group 6*****
0-6000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

NOTE: This is a 5.0-hour job for Group 6
After failure can claim additional 3.0 hour for performing Oil Rail Cleaning Procedure. There is a $100 miscellaneous allowance for purchase of SOLAS tape (if required by Marine Classification Society). Travel and mileage will only be authorized for one engine for multiple engines being reworked in a vessel. On vessels with multiple affected engines every effort should be made to complete the service letter on all engines on the vessel on the same trip. Please reference the other engine serial numbers in the claim story.