PSP FOR REPLACING THE HEUI HYDRAULIC PUMP GROUP OR INSTALLING A PUMP REPAIR KIT ON CERTAIN 3408E AND 3412E, 836, 24H, 669D, 771 D, 773D AND 775D, D9R AND 988F II AND 990 II, 834B, 631E, 633E, 637E, 651E AND 657E, PM-565 AND AD40 AND AE40 - PS5378 - M Caterpillar

November 10, 1997
(Revised March 2001)
SEBE6299-10
November 10, 1997
(Revised March 2001)
U-336
A-301
AU-272
S-165
H-89
O-288
After failure only PRODUCT SUPPORT PROGRAM FOR REPLACING THE
HEUI HYDRAULIC PUMP GROUP OR INSTALLING A
PUMP REPAIR KIT ON CERTAIN 3408E AND 3412E
INDUSTRIAL ENGINES; 836 COMPACTORS; 24H
MOTOR GRADERS; 669D, 771D, 773D AND 775D
TRUCKS; D9R AND D10R TRACK TYPE TRACTORS;
988F II AND 990 II WHEEL LOADERS; 834B WHEEL
TRACTORS; 631E, 633E, 637E, 651E AND 657E
SCRAPERS; PM-565 COLD PLANERS; AND AD40 AND
AE40 ARTICULATED DUMP TRUCKS
7729   PS5378
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
"PS5378" 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: This Revised Service Letter replaces the November
10, 1997 (Revised August 2000) Service Letter.
Changes have been made to the Termination Date.

April 30, 2003

The HEUI hydraulic pump group may fail which will result in the
engine not running.

Model Identification Number
3408E 7PR1-Up
3412E 4CR1-Up
836 7FR1-Up
24H 7KK1-Up
769D  5TR1-70, 72-135, 137-173, 175-207, 209-256, 258-
355,
357-388, 390-424, 429-568, 570-Up
771D  6JR1-Up
773D  05A11732
7ER1-280, 282-Up
775D  6KR1-Up
D9R 7TL557-Up
8BL831-Up
D10R  3KR1-Up
AD40
AE40II 11129-11132
2ZS25, 31-34, 58-64, 73-76, 91-92
988F II 2ZR1-Up
990 II 05A11309, 11330, 11605-11610, 11274
4FR1-206, 209-238, 240-246, 248-257, 259, 260,
262-269, 272, 273, 275-Up
834B  7BR1-Up
631E  05A11205, 11370, 11389, 11588, 11699-11701
1AB1640-1670, 1672-1689, 1691-1694, 1696-1710,
1712-1714, 1716, 1719-Up
1NB1390-Up
633E  2PS290-Up
637E  1FB1-Up
651E  05A11544, 11574
4YR1-193, 196-Up
657E  5YR1-Up
6TR1-Up
7KR1-Up
PM-565 3TK1-Up
8GS1-Up
69D 05A11091-11097, 11512-11515
9SS169-178
73D 05A11481
1GW118-121
Spare or 99C2444, 2728, 2894, 2932, 2955, 2943, 2991
Replacement
Engines

Quantit Part Number Description
y
1 6V1197  Seal-O-Ring
1 6V8676  Seal-O-Ring
1 9X7734  Seal-O-Ring
2 0336027  Seal-O-Ring
1 0R9927 Pump Group
or
1 1546732 Pump Repair Kit (Use with 1440835 and
or 1349406 Pump Groups only)
1 1618627  Plug Kit

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.
1. Connect the diagnostic equipment (ET or ECAP) to the
Electronic Control Module (ECM) in order to monitor the
injection actuation pressure.
2. Unplug the injection actuation pressure control valve.
3. Crank the engine and note the injection actuation pressure.
4. Remove the allen head plug.
5. Turn the load sensing screw in approximately two turns.
6. Crank the engine and note the injection actuation pressure.
7. 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 0R9927 Pump Group if the
pressure can not be obtained by turning the compensator
adjustment screw.
NOTE: A 1546732 Repair Kit may be used for 1440835 and
1349406 Pump Groups instead of replacing the
1440837 Pump Group. The pump should be updated
with a 1616827 Plug Kit if the 1546732 Pump Repair
Kit is used.

Product Caterpillar Dealer Suggested Customer
smu/age   Suggested
whicheve
r comes
first
Parts Labor Parts Labor Parts Labor
(D/N) Hrs Hrs (C/L) Hrs
(Cost)  (Sell)
0-5000 100% *100% 0 0 0 0
5001- 67.7% *50% 0 0 25% 50%
7500
7501- 33.3% 0 0 0 50% 100%
10000
NOTE: * Claim actual R&I time up to a maximum of 4.0
Hours on all models except for the 836, 988F 834B
And AD/AE40II. These models may claim actual hours
up to a maximum of 6.0 hours.
NOTE: If a 1546732 pump repair kit is claimed, an
Additional 2.0 hours may be claimed for installing
The repair kit. This is applicable up to 10,000
Hours.
NOTE: When claiming against a spare engine, use the
Appropriate 99Z----- code for spare components.

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