PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP GROUP ON CERTAIN 3408E AND 3412E POWERED 836 COMPACTORS; 834B AND 844 WHEEL DOZERS; 988F AND 990 WHEEL LOADERS; 5110B EXCAVATORS; 24H MOTOR GRADERS; 631E, 633E, 637E, 651E, AND 657E SCRAPERS; AD40, Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP GROUP ON CERTAIN 3408E AND 3412E POWERED 836 COMPACTORS; 834B AND 844 WHEEL DOZERS; 988F AND 990 WHEEL LOADERS; 5110B EXCAVATORS; 24H MOTOR GRADERS; 631E, 633E, 637E, 651E, AND 657E SCRAPERS; AD40,

Usage:

SEBE8013-01

June 9, 2002
(Revised October 2002)
U-123
A-94
AU-92
S-92
H-91
O-108

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP GROUP ON CERTAIN 3408E AND 3412E POWERED 836 COMPACTORS; 834B AND 844 WHEEL DOZERS; 988F AND 990 WHEEL LOADERS; 5110B EXCAVATORS; 24H MOTOR GRADERS; 631E, 633E, 637E, 651E, AND 657E SCRAPERS; AD40, AE40, AD45, 69D, 73D, 769D, 771D, 773D, AND 775D TRUCKS; D9R AND D10R TRACK-TYPE TRACTORS; PM-565B ASPHALT PROFILERS
1714		PS50413

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50413" as the Part number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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.

NOTE: This program can not be administered unless the customer is using either the preferred CH-4, CG-4, or CF-4 Oil.

NOTE: This program replaces Product Support Program PS5378.

NOTE: This Revised Service Letter replaces the June 9, 2002 Service Letter. Changes have been made to the Affected Product.

TERMINATION DATE

June 30, 2004

PROBLEM

The HEUI pump group (including 1440835, 1440837, 1546732, 1691034, 1691035, 0R9927, and related earlier pump group generations) may fail which will result in the engine not running.

AFFECTED PRODUCT

Use the Engine S/N Range for the affected Pump build period in this service program as shown in the table below. The corresponding approximate model S/N ranges are only shown for reference. Each machine is eligible for these updated parts only once. If an engine within the affected product range previously had a 2014202 or 0R2236 Pump installed, or an older pump was updated with the 2014203 Repair Kit to the new configuration, it is not eligible for this program.

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Model	Model S/N Range	Engine S/N Range
834B	7BR1-Up	99C1-7189
836	7FR1-Up	99C1-7189
988F	2ZR1-Up	99C1-7189
631E	1AB1640-Up 1NB1390-Up	99C1-7189
633E	2PS290-Up	99C1-7189
637E	1FB660-Up	99C1-7189
657E	6PR1-Up 7KR1-Up	99C1-7189
769D	5SS1-626 5TR1-Up	99C1-7189
771D	6YS1-430 6JR1-Up	99C1-7189
69D	9SS169-180 9XS1-Up 05A11091-11097, 11512-11515	99C1-7189
AD40	1YZ1-Up 05A10147, 10148, 10345, 10395, 10810-10813, 11129-11132	99C1-7189
AE40	1ZZ1-Up 2ZS1-Up BLW181-Up	99C1-7189
AD45	BKZ181-Up	99C1-7189
D9R	7TL557-Up 8BL830-Up	99C1-7189
PM-565	3TK113-123	99C1-7189
PM-565B	8GS1-214	99C1-7189
844	2KZ1-402	80M1-4511
990	4FR1-624	80M1-4511
24H	7KK1-206	80M1-4511
651E	4YR1-214	80M1-4511
657E	5YR1-318 6TR1-403	80M1-4511 99C1-7189
773D	7CS1-857 7ER1-Up	80M1-4511
775D	8AS1-546 6KR1-Up	80M1-4511
73D	1GW118-122 05A11481	80M1-4511
D10R	3KR1-1684 AKT188, 190, 191, 194	80M1-4511 5JJ257, 260, 261, 263
5110B	AAA1-311	80M1-4511

PARTS NEEDED

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Qty	Part Number	Description
1	0R2236	PUMP GP-BASIC
1	6V1197	SEAL-O-RING
1	6V8676	SEAL-O RING
1	9X7734	SEAL-O RING
1	0336027	SEAL-O RING
4	5M2894	WASHER

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

On 3408E Machine Engines;

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PART Hours/Age, whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
PART Hours/Age, whichever comes first	Parts	Labor Hrs*	Parts	Labor Hrs	Parts	Labor Hrs
0-6000 0-60 mos	100%	5.0	0	0	0	0
6001-10000 0-60 mos	33.3%	2.5	0	0	50%	2.5
*NOTE: This is a 5 hour job. Actual hours permitted up to maximums noted above.

On 3412E Machine Engines;

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PART Hours/Age, whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
PART Hours/Age, whichever comes first	Parts	Labor Hrs*	Parts	Labor Hrs	Parts	Labor Hrs
0-6000 0-60 mos	100%	4.0	0	0	0	0
6001-10000 0-60 mos	33.3%	2.0	0	0	50%	2.0
*NOTE: This is a 4 hour job. Actual hours permitted up to maximums noted above.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Reference Special Instruction, REHS0282, "Installation Procedure of the HEUI Pump Compensator Standby Plug for 3408E and 3412E".

If the HEUI pump is not providing the required injection actuation pressure during engine cranking, perform the following procedure.

Connect the diagnostic equipment (ET or ECAP) to the Electronic Control Module (ECM) in order to monitor the injection actuation pressure.
Unplug the injection actuation pressure control valve.
Crank the engine and note the injection actuation pressure.
Remove the allen head plug.
Turn the load sensing screw in approximately two turns.
Crank the engine and note the injection actuation pressure.
Connect the injection actuation pressure control valve when the procedure is completed. If the injector actuation pressure increases after the load sensing screw is turned, installing the proper one piece compensator plug should correct the condition. If the pressure doesn't increase, the pump requires rebuilding or replacement.
Follow the procedure in the Reference publication for installing the appropriate length compensator plug from the 1618627 Plug Kit.
Replace the failed pump with a new 0R2236 Pump Group if the pressure can not be obtained by turning the compensator adjustment screw. While the pump is removed, also inspect the pump drive system and add the (4) new 5M2894 hardened washers on the (4) 5P0076 mounting group retaining bolts, realign pump mount, and tighten fasteners as specified here;