PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP ON CERTAIN 330D, 336D, AND 340D EXCAVATORS, 140M, AND 160M MOTOR GRADERS, D6R, AND D6T TRACK-TYPE TRACTORS, 2390, 2491, 511, 521, 522, 532, AND 552 TRACK FELLER BUNCHERS, 627G, 637D, 637E, AND 637G Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP ON CERTAIN 330D, 336D, AND 340D EXCAVATORS, 140M, AND 160M MOTOR GRADERS, D6R, AND D6T TRACK-TYPE TRACTORS, 2390, 2491, 511, 521, 522, 532, AND 552 TRACK FELLER BUNCHERS, 627G, 637D, 637E, AND 637G

Usage:

REBE8437-00

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13Sep2012

U-493

A-388

D-420

O-454

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE HEUI PUMP ON CERTAIN 330D, 336D, AND 340D EXCAVATORS, 140M, AND 160M MOTOR GRADERS, D6R, AND D6T TRACK-TYPE TRACTORS, 2390, 2491, 511, 521, 522, 532, AND 552 TRACK FELLER BUNCHERS, 627G, 637D, 637E, AND 637G WHEEL TRACTOR-SCRAPERS, AND 814F WHEEL DOZERS, AND 815F SOIL COMPACTORS, AND 816F LANDFILL COMPACTORS
1714		PS52292

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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 "PS52292" 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.

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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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TERMINATION DATE

30Sep2014

PROBLEM

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The existing HEUI pump can fail on certain 330D, 336D, and 340D Excavators, 140M, and 160M Motor Graders, D6R, and D6T Track-Type Tractors, 2390, 2491, 511, 521, 522, 532 and 552 Track Feller Bunchers, 627G, 637D, 637E, and 637G Wheel Tractor-Scrapers, and 814F Wheel Dozers, and 815F Soil Compactors, and 816F Landfill Compactors, causing hard starting, no start, or poor engine performance.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
330D	EAH01031-01635 ERN00339-00415 FFK00407-00510 GGE00753-00904 LCJ00250-00318 MEY00362-00454 NBD01055-01474 PFC00173-00190 RAS01052-01314 THJ00322-00380
330D FM	L2K00227-00228, 1300-1305
330D FM BUTT N	E4K01500-01509
330D FM HEEL	H3K00369-00371, 1400-1416
330D L	B6H00652-00654 JLP00593-00946 LRM00355-00593 MWP02342-03385 NEF00198-00261, 263-268, 270-276 R2D00201-00284 RDK00159-00178
330D L OEM	H3D00256-00337, 390-391 M3D00100-00103
330D LN OEM	GMN00103-00106
330D MH	PEL00175-00186
330D MH FCR	LEM00209-00286, 20101
330D MH HCR	C5K00224-00253
330D OEM	D3D00318-00519
330D WH	JJM00223-00243
336D	JBT00260-04308, 4310-4333 JER00162-00301, 303 KKT00107-01069, 99999 PGW00148-00192
336D HVG UHD OEM	M3N00100-00120
336D L	DTS00186-00213 J2F00151-00656 JBF00158-00177 KDJ00265-00393 LMG00161-00175 M4T00101-02224 MPL00278-00527 NLS00156-00238 PPN00271-00796 PRF00159-01224 SKE00173-00229 W3K00201-01673 WET00236-00350 WRK00177-00471, 473
336D L OEM	J6D00200-00376, 382-567, 569-617 L5X00100-00556, 558-565, 570-582, 584-591, 596-604, 610-612, 616-621, 625-627, 631-635, 639-641, 646, 659-661, 671, 692-693, 698, 701, 21387
336D L SB OEM	M2P00100-00108
336D LN	MYG00101-00494 MYP00114-00191
340D L	JTN00130-00437

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*****Group 2*****
140M	B9G00100-00104, 107-198, 200-239, 241-247, 249-251 D9G00100-00208, 1001-1190, 1300-1383
160M	B9E00196-00570, 700-873 B9L00254-00506 B9T00100-00183 D9T00100-00182, 300-311

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*****Group 3*****
D6R III	JEK00185-00401
D6R III LGP	LGP00366-00656
D6R III XL	EXL00200-00306
D6R III XW	EXW00141-00144
D6R LGP X	S6Y00100-00194
D6R X	C6Z01000 S6X00101-01146, 1148, 1155, 1159, 1161, 1164, 1167, 1171, 1175
D6R XL	A6M00100-00101
D6R XL X	S6T00101-00524, 526-527, 533, 535, 537, 539
D6T	JHB00223-00569 PEZ00113-00733 SMC00201-00595
D6T LGP	KJL00605-01294 LKJ00200-00665 SNK00175-00177
D6T P LGP	WCG00389-00629
D6T P XL	WFH00342-00551 ZEB00200-00219
D6T P XW	DJG00359-00535 RLW00225-00255
D6T XL	GCT00266-01102 LAE00140-00756, 758, 850-872 LAY00743-01667
D6T XW	LBD00150-00210 SKL00408-00762

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*****Group 4*****
2390	P3H00250
2491	P5J00250
511	51100293-00312, 500-503
521	52100323-00353, 500-507
522	52200253-00276, 500-522, 56885, 56895
532	53200177-00183, 500-501
552	55200150-00159, 500-501, 56832, 56841

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*****Group 5*****
627G	CEZ00252, 452 DBZ00835, 863, 876
637D	21W00406, 410-502 22W00451, 469, 474, 605, 611, 622, 625, 627, 633, 639-642, 644-645, 647-742, 744-1178 23W00489, 509, 523, 551, 570, 573-574, 576, 579, 581-582, 585-586, 588, 590-591, 593, 595, 597, 599-600, 602, 604-607, 609, 611-614, 616-627, 629-815, 817-1142 4JB00033-00039
637D SCRAPER	70W00421, 455, 457-462
637E	1HB00387-00479, 505-711, 749, 810-951, 980, 1100
637G	DEY00205-00209, 237 DFJ00225-00488
814F	BXG00160-00181
815F	BYN00389-00737, 900-910, 912-913
816F	BZR00229-00393, 500-501

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	6V3305	ADAPTER-ELBOW
2	6V5839	WASHER-HARD
2	6V7981	BOLT
1	6V8629	ADAPTER-ELBOW
6	10R7222	INJECTOR GP-FUEL
1	20R1635	PUMP GP -B
1	1286841	ADAPTER-ELBOW
1	2147567	SEAL-O-RING-STOR
1	2147568	SEAL-O-RING-STOR
1	2287089	SEAL-O-RING-ORFS
2	2287092	SEAL-O-RING-ORFS
12	2359651	BOLT-SOCKET HEAD
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3816796	LINE AS-HYBRID
1	3877151	TUBE AS-OIL
1	3877153	TUBE AS-OIL
1	3960385	ADAPTER-STR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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	6V3305	ADAPTER-ELBOW
2	6V5839	WASHER-HARD
2	6V7981	BOLT
2	6V8636	ADAPTER-STR
1	8T5389	ADAPTER-ELBOW
6	10R7222	INJECTOR GP-FUEL
1	20R1644	PUMP GP -B
1	1286841	ADAPTER-ELBOW
1	2147567	SEAL-O-RING-STOR
3	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
2	2287089	SEAL-O-RING-ORFS
2	2287092	SEAL-O-RING-ORFS
12	2359651	BOLT-SOCKET HEAD
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3603679	PLUG-HD STOR
1	3877154	TUBE AS
1	3877159	TUBE AS-OIL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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*****
2	6V5839	WASHER-HARD
2	6V7981	BOLT
2	6V8636	ADAPTER-STR
1	8T5389	ADAPTER-ELBOW
6	10R7221	INJECTOR GP-FUEL
1	20R1636	PUMP GP -B
1	1286841	ADAPTER-ELBOW
2	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
2	2287089	SEAL-O-RING-ORFS
2	2287092	SEAL-O-RING-ORFS
12	2359651	BOLT-SOCKET HEAD
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3603679	PLUG-HD STOR
1	3877154	TUBE AS
1	3877159	TUBE AS-OIL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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*****
2	6V5839	WASHER-HARD
2	6V7981	BOLT
1	6V8629	ADAPTER-ELBOW
2	6V8636	ADAPTER-STR
6	10R7222	INJECTOR GP-FUEL
1	1286841	ADAPTER-ELBOW
3	2147568	SEAL-O-RING-STOR
1	2275904	SEAL-O-RING
2	2287089	SEAL-O-RING-ORFS
2	2287092	SEAL-O-RING-ORFS
12	2359651	BOLT-SOCKET HEAD
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3603679	PLUG-HD STOR
1	3840607	PUMP GP -B
1	3877151	TUBE AS-OIL
1	3877153	TUBE AS-OIL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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	6V3305	ADAPTER-ELBOW
2	6V5839	WASHER-HARD
2	6V7981	BOLT
1	6V8629	ADAPTER-ELBOW
6	10R7225	INJECTOR GP-FUEL
1	20R1636	PUMP GP -B
1	1286841	ADAPTER-ELBOW
1	2147567	SEAL-O-RING-STOR
1	2147568	SEAL-O-RING-STOR
1	2287089	SEAL-O-RING-ORFS
2	2287092	SEAL-O-RING-ORFS
12	2359651	BOLT-SOCKET HEAD
1	2385081	SEAL-O-RING-STOR
1	2385082	SEAL-O-RING-STOR
1	3877154	TUBE AS
1	3877159	TUBE AS-OIL
1	3960385	ADAPTER-STR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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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1. Refer to the "Injection Actuation Pressure-Test" or the "Injection Actuation Pressure Control Valve Circuit-Test" in the Troubleshooting manual and Special Instruction, REHS3819 for the machine being worked to correctly diagnose the failure. Refer to Special Instruction, REHS7902,"Procedure for Installing the New Unit Injector Hydraulic Pump Gp on Certain C9 Engines", for details to update existing engine configurations to the new design.

2. If a HEUI pump is found to have a bearing failure as per Step 7 in Special Instruction, REHS3819, this program will cover the replacement of a set of six injectors and the flushing of the cylinder head oil rail passage per the Oil Rail Cleaning Procedure in REHS3819 per the participation allowance table for the Affected Product being worked on.

3. Include in the claim story the diagnostic procedure title or media number and procedure step at which the pump was found defective.

The ECM warranty report downloads, datalogs, pictures, and any special test results as directed by the troubleshooting, and repair procedures are to be uploaded to SIMSi.

Checklists that are packaged with replacement parts are to be completed and packaged with failed parts. Refer to the Parts Disposition.

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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*****
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 6.7-hour job for Group 1
If a failure is claimed per step 2 in the required actions of this letter, 1.5 hour additional labor for completing the Oil Rail cleaning Procedure in REHS3819 will be allowed.

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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*****
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 6.7-hour job for Group 2
If a failure is claimed per step 2 in the required actions of this letter, 1.0 hour additional labor for completing the Oil Rail cleaning Procedure in REHS3819 will be allowed.

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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*****
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 6.7-hour job for Group 3
If a failure is claimed per step 2 in the required actions of this letter, 1.5 hour additional labor for completing the Oil Rail cleaning Procedure in REHS3819 will be allowed.

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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*****
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 7.0-hour job for Group 4
If a failure is claimed per step 2 in the required actions of this letter, 1.5 hour additional labor for completing the Oil Rail cleaning Procedure in REHS3819 will be allowed.

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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*****
0-3000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
3001-6000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

NOTE: This is a 6.5-hour job for Group 5
If a failure is claimed per step 2 in the required actions of this letter, 1.5 hour additional labor for completing the Oil Rail cleaning Procedure in REHS3819 will be allowed.

PARTS DISPOSITION

***** NACD *****
Hold the HEUI pump and/or injectors for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Complete the checklist form supplied with the replacement part and retain it with the failed part. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.

***** EAME, LACD, and APD *****
Hold the HEUI pump and/or injectors for 30 days for a possible Parts Return Request (PRR). Complete the checklist form supplied with the replacement part and retain it with the failed part. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.

If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.