PRODUCT SUPPORT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C9 MACHINE AND INDUSTRIAL ENGINES Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C9 MACHINE AND INDUSTRIAL ENGINES

Usage:

SEBE9065-01

February 13, 2005
(Revised February 2005)
U-44
A-32
D-39
O-38
TA-1

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C9 MACHINE AND INDUSTRIAL ENGINES
1251		PS41715

NOTE: This Program can 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 "PS41715" as the Part number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, 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 Revised Service Letter replaces the February 13, 2005 Service Letter. Changes have been made to the Affected Product.

TERMINATION DATE

February 28, 2006

PROBLEM

The spring /check valve within the HEUI pump is experiencing fatigue failure, causing hard starting or rough running.

AFFECTED PRODUCT

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Model	Identification Number
CIPI	0EM683, 686, 791, 801-803, 805-808, 810, 829, 830, 836-840, 842-858, 937-945, 948
TK711	10100192-00193 00195-00201
TK721	10200192-00200 00203
TK722	10300196-00200
TK732	10400191
12H	12539-42, 44-60, 62, 66-70, 72-77, 79-93, 95-133, 145 AMZ361-363, 365-367, 369, 373, 374, 376-378, 380-409, 411-430, 432-433, 435-437, 440-446, 448-464, 466-521 CBK294, 341, 343-345, 347, 351, 352, 354-366, 368-372, 374-389, 391, 393-398, 400-410, 412-466, 468-488, 490-508, 510-514, 516-525, 527-533, 537, 546, 550, 592, 639
TK741	20200185
C9 CAPT	4ZF7559, 7565, 7574, 7590, 7602, 7617, 7619, 7624, 7628, 7639-7640, 7642-7643, 7645-7646, 7648, 7678, 7680, 7687-7688, 7691, 7768, 7795, 7874, 7942, 7987, 7999, 8005, 8123, 8181, 8184, 8205, 8223, 8233, 8297, 8311, 8360, 8367, 8370, 8377, 8393, 8396-8398, 8400-8401, 8405, 8406, 8411, 8424, 8432, 8435, 8437, 8439, 8490, 8494, 8509, 8524, 8559, 8560, 8565, 8601, 8609, 8704, 8710, 8718, 8752, 8813, 8854, 8868, 8874, 8879, 8887, 8893, 8898-8904, 8910, 8915, 8945, 8993, 9003, 9075, 9077, 9083, 9086, 9088, 9090, 9093, 9097, 9102, 9116, 9120, 9125, 9131, 9174, 9224, 9251, 9261, 9272, 9321, 9359, 9371, 9373, 9376, 9379, 9384, 9385, 9393, 9395, 9407, 9413, 9417, 9421, 9422, 9426, 9437, 9444, 9447, 9452, 9453, 9458, 9477, 9478, 9486, 9492, 9512, 9535, 9550, 9558, 9573, 9608, 9625, 9662, 9670, 9700, 9709, 9711, 9725, 9726, 9732, 9742, 9745, 9801, 9822, 9825, 9837, 9841, 9874, 9877, 9918, 9926, 9939, 10029, 10041, 10118, 10131, 10148, 10180, 10182, 10189, 10192, 10195, 10197, 10203, 10211, 10235, 10277, 10279, 10281, 10294, 10318, 10325, 10337, 10340, 10348-10350, 10361, 10368, 10379, 10389, 10393, 10397, 10402, 10405, 10418, 10427, 10429, 10432-10433, 10438, 10440-10446, 10472-10479, 10522, 10524, 10527, 10534, 10542, 10556, 10561, 10563, 10565, 10573, 10577, 10585, 10622, 10641-10643, 10654, 10658, 10660, 10678, 10692, 10723, 10726, 10741, 10755, 10759, 10795, 10806, 10809, 10815, 10822, 10839, 10842, 10846, 10849, 10855, 10857, 10863, 10877-10879, 10887, 10889-10890, 10914, 10918, 10920, 10921, 10978, 10981, 10989, 10999, 11005, 11006, 11009, 11012-11014, 11017, 11019, 11026, 11038, 11040, 11041, 11047, 11062, 11065, 11066, 11089, 11097, 11100, 11107, 11111, 11115, 11116, 11118, 11123, 11125, 11138, 11141, 11145, 11156, 11158, 11163, 11167, 11168, 11171, 11177, 11178, 11185, 11193, 11194, 11201, 11215, 11218, 11222, 11223, 11232, 11242, 11257, 11270, 11272, 11292, 11302, 11306, 11314, 11334, 11343, 11353, 11359, 11360, 11380, 11384, 11387, 11394, 11399, 11400, 11407, 11409, 11413, 11418, 11421, 11428, 11430, 11435, 11436, 11450, 11455, 11465, 11466, 11474, 11495, 11496, 11498, 11500, 11508, 11510, 11516, 11525, 11532, 11534, 11561, 11569, 11570, 11591, 11596, 11602, 11607, 11608, 11615, 11650, 11673, 11677, 11679-11680, 11703, 11705, 11707, 11709, 11710, 11717, 11724-11725, 11734, 11739, 11748, 11754, 11763, 11765, 11768, 11781, 11783, 11786, 11793, 11796, 11800, 11808, 11809. 11812, 11814, 11815, 11854, 11901, 12114, 12161, 12290, 12629
C9	CLJ3207, 4039-4043, 4058, 4074-4076, 4090-4106, 4108-4111, 4113-4155, 4157-4169, 4171-4177, 4179-4189, 4192-4211, 4216, 4217, 4219-4301, 4303-4319, 4321-4324, 4328-4333, 4336-4355, 4357-4369, 4371-4392, 4394-4408, 4420, 4423-4482, 4485, 4486, 4490-4500, 4503-4513, 4515-4550, 4552-4576, 4578-4596, 4598-4613, 4615-4620, 4622-4632, 4634-4653, 4655-4663, 4665-4683, 4686-4696, 4699-4708, 4710, 4712-4726, 4728-4814, 4817, 4819-4851, 4853-4867, 4870-4880, 4882-4903, 4905-5001, 5003-5010, 5013-5018, 5021-5047, 5049, 5050, 5053-5078, 5080-5127, 5129-5241, 5243-5244, 5247-5251, 5253-5264, 5266, 5267, 5269-5280, 5282-5288, 5291-5297, 5300-5325, 5327-5329, 5331-5354, 5359-5361, 5367, 5377-5379, 5386, 5393, 5399, 5400, 5404, 5465, 5494, 5496
D6R SERIES II X	AAX358, 362-364, 368, 371, 374-398, 400-405, 407-411, 413-425, 427-464, 466-468, 470-478, 480-498, 500-510, 512, 513, 515-531, 533, 534, 537-556, 558-560, 562-578, 580, 581, 583-604, 606-608, 610, 612-633, 635-652, 654-665, 667-674, 679, 698-700, 738 AEP212, 213, 216-253, 255-265, 267-271, 273-332, 334-355, 376, 386 AGM102-104 BMJ131-133, 135-136, 139 BMY277, 289, 293, 295-308, 310, 311, 313-338, 345, 348 BPS101, 103, 105, 106 BRZ106, 108-110, 112-114, 116-126, 130 CAD147-149, 152-163, 169, 172, 192 DAE130-132, 134-139, 141-154, 156-157 FDT117, 121, 136-140, 142-171, 173-178, 180-197, 199-203, 205-215, 224, 258, 278
D6R SERIES II L	ACJ100, 102-107, 109 ADE290, 291, 294-301, 303-323, 325-369, 371-420, 422-449, 451-487, 489-502, 504-525, 527-529, 532-533, 539, 548, 571 BNC261, 263-267, 269-273, 275-277, 279-281, 283-304, 306-310, 311, 313-315, 317, 319, 326 BPP96-98 BPZ115-00121, 123-136, 140, 141, 143-160, 162-164
D6R SERIES II	AEM100-104 AFM116-124, 126 BLE176-188, 191-203, 205-214, 216, 218-219, 221-226, 228-229, 235, 246-247 BLT173-209, 211 BMK101, 115, 120, 122, 124-126, 128-131, 146-148, 153 BNL100, 101, 105 BPM102 BRJ121, 124-141, 145
330C	B1K178, 179, 181-195, 199 B2L203, 204, 206-210, 212-220 B3M197, 198 B4N187, 188, 190-198 BTM189-198 CGZ456, 457, 461, 463, 464, 466, 468, 470-478, 480, 482-503, 505, 506, 508-510, 512-516, 518-534, 536-541, 542-543, 545-565, 567-615, 620 CYA284-298, 300-302, 304-307, 309-327, 329-380, 382-422, 424-443, 445-459, 461-482, 484-518, 520-522, 524-533, 535-538, 540-542, 544, 546, 547, 558, 574, 699, 701-703 GAG306-328, 330-349, 351-373, 377, 380, 383-385 JAB600-607, 609-633, 637, 638, 640-642, 644, 645, 647-649, 651, 653-663, 665-676, 678-696, 702-709, 711-715 JCD290, 292, 294, 295, 297, 298, 299-313, 315-316 JNK243-252, 254, 257-259, 260-286, 290 KDD531, 532, 534-537, 539-541, 543-545, 547-600, 602-614, 616-621, 623-626, 628-630, 635, 638-642, 646-650, 653-657, 661-666, 669-671, 676-680, 682, 684-693, 696-702, 705-708, 710, 713, 717, 718, 720, 721, 723-726, 728, 729, 731, 732, 734-737, 739, 740, 742, 743, 745, 747, 749, 755, 756, 758, 759, 761, 762, 764-767, 771, 772, 774, 775, 777, 778, 780, 784, 790, 795, 797 MCA406-409, 411, 413, 417, 423, 426, 427, 429-458, 460-497, 499-506, 508-534, 536-543, 545-547, 549-577, 579-591, 593-623, 625-635 MKM309, 310 RBH231-235, 237-240, 242, 243, 247
330C L	CAP984, 986-989, 993, 995, 1002, 1005, 1007, 1008, 1010, 1013, 1015-1021, 1023, 1025, 1026, 1029-1048, 1050-1062, 1064-1081, 1083-1087, 1089-1092, 1094-1138, 1140-1157, 1159-1179, 1181-1185, 1187-1191, 1193-1216, 1218-1256, 1258-1265, 1267-1272, 1274-1278, 1280-1485, 1487, 1489-1500, 1503, 1514, 1552 DKY1057, 1494, 1495, 1497, 1501, 1502, 1505-1510, 1512, 1513, 1523, 1526, 1529-1532, 1534, 1537-1543, 1545-1551, 1553-1570, 1572-1587, 1589, 1591, 1593-1599, 1601-1623, 1625-1669, 1672-1695, 1697-1754, 1756, 1757, 1759-1773, 1776-1778, 1781, 1782, 1794-1796, 1799, 1802, 1803, 1807-1821, 1823-1834, 1836-1889, 1891-1906, 1908-1923, 1925-1963, 1965-2004, 2006-2023, 2025, 2027-2041, 2044-2057, 2059-2068, 2070-2075, 2078-2105, 2107-2124, 2127-2156, 2158-2160, 2162-2179, 2182-2186, 2188-2196, 2198-2219, 2221-2223, 2225-2237, 2240-2299, 2301-2311, 2313-2321, 2324-2326, 2338, 2340, 2341, 2343-2346, 2348, 2350, 2354, 2355, 2364, 2425, 2476 HAA369, 371, 372, 375-380, 382-386, 388-390, 392-414, 416, 418-450, 452, 454-457, 459
330C MH	D3C232, 233, 235, 238, 240-247, 249-258
637G	CEH254-259, 350, 351, 353-359, 361-364, 366
627G	CEX277, 284, 286-293, 295, 296, 298-315, 400-418, 420-433, 435-437, 439-452, 454, 458, 460, 461, 470, 471, 479
973C	BCP109-115, 117-146, 149

PARTS NEEDED

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Qty	Part Number	Description
1	2664455	KIT ? CHECK VALVE
1 *	10R2981	PUMP
1 **	10R2982	PUMP

*NOTE: Order only if the valve spings in the pump are broken. For use with fuel tranfer pump. **NOTE:Order only if the valve spings in the pump are broken. For use without fuel tranfer pump.

ACTION REQUIRED

This procedure should be followed only if a clean working environment is available such as the dealership/customer shop. Do not attempt to rework the pump in a dirty work environment. The HEUI pump will fail if debris is in the system or the debris will fail an injector.

Notice: Failure to install the "Service Bolt", included in check valve kit, or use vise as described in REHS2422 prior to removing fuel transfer pump mounting bolts WILL CAUSE THE HEUI PUMP TO SEPARATE AND FAIL! Follow Special instructions REHS2422 carefully!

NOTE: RMHS2422 is the translated version of REHS2422.

Illustration 1

Verify part number of HEUI pump. (See Illustration 1)

2323911 HEUI pump 232-3912 HEUI pump

2044944 HEUI pump 204-4945 HEUI pump

Verify s/n on HEUI pump is in the following range. (See Illustration 1)

9440054815 ? 9440075582 9450054950 - 9450076214

9110085776 ? 9110099469 9120076215 ? 9120111408

NOTE: If HEUI pump serial number is not in range listed above?STOP.

Verify that HEUI pump has not already been reworked by looking for a "CV" stamped on the HEUI pump. (See Illustration 1)

NOTE: If HEUI pump is stamped "CV"?STOP

Install the 2664455 Check Valve Kit using the rework procedure in Special Instruction REHS2422.

NOTE: The special instructions MUST be followed completely or pump failure may occur. Follow each step including proper torque values, sequence and use of the "service bolt".

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
0-0 0-12 mos	100%	2.4	0	0	0	0
NOTE: Claim either 0.4 hours for inspection or 2.4 hours for inspect and replace. NOTE: Additional labor hours will be covered for various cab configurations.