PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE FUEL INJECTION PUMPS ON CERTAIN C7 AND C9 ON-HIGHWAY TRUCK ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE FUEL INJECTION PUMPS ON CERTAIN C7 AND C9 ON-HIGHWAY TRUCK ENGINES

Usage:

REBE2409-01

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31Aug2007

(Revised 22Oct2007)

U-425

A-351

TT-29

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND/OR REPLACING THE FUEL INJECTION PUMPS ON CERTAIN C7 AND C9 ON-HIGHWAY TRUCK ENGINES
1251 1252 1714		PI10620

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10620" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10620" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 13Aug2007 Service Letter. Changes have been made to Owner Notifiation Letter for NHTSA.

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PROBLEM

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This Product Improvement Program is a Safety Recall in accordance with the US National Traffic and Motor Vehicle Safety Act and the Canadian Motor Vehicle Safety Act. A fuel pump failure will dilute the engine oil with fuel and may cause the turbocharger to fail and cause loss of throttle control and excessive smoke, both of which may result in a situation where a vehicle crash could occur. It is a violation of US Federal law for a dealer to deliver a new motor vehicle or new or used engine covered by this Safety PIP until the PIP has been completed.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C7	C7S00735, 962, 967, 1033, 1358, 1570, 1657, 1799, 1809, 1812, 1819, 1837, 1905, 1908, 1915, 1919, 1933, 1972, 1998, 2002, 2018, 2023-2024, 2040, 2070, 2072, 2075, 2086, 2088, 2106-2107, 2113, 2119, 2138, 2140, 2146, 2156, 2158, 2165-2166, 2172, 2177, 2182, 2196, 2201-2202, 2222, 2252, 2262, 2266, 2285, 2289, 2301-2302, 2304, 2317, 2321, 2325, 2327, 2333, 2335, 2380, 2384, 2417-2418, 2428, 2430, 2435-2438, 2440, 2442, 2444, 2448-2451, 2458, 2461, 2464-2465, 2469-2470, 2473-2474, 2479, 2483-2484, 2487, 2489, 2492, 2494, 2496, 2499, 2506-2507, 2511-2512, 2516, 2520, 2522, 2525, 2534-2537, 2540, 2542, 2549-2550, 2552, 2555, 2577, 2595, 2607, 2651, 2673, 2676-2678, 2680, 2683, 2687, 2691, 2693, 2697-2698, 2704-2705, 2709, 2711, 2714, 2716, 2718, 2721, 2725, 2727, 2741, 2752, 2758, 2768, 2782, 2789-2792, 2794-2796, 2799-2800, 2802, 2804-2806, 2808-2811, 2814-2816, 2820, 2828, 2830-2832, 2836, 2840-2841, 2843, 2846, 2850-2851, 2856-2858, 2874-2875, 2879, 2889-2890, 2905, 2912, 2922, 2936-2937, 2942, 2944-2945, 2953, 2955, 2957, 2960, 2963-2964, 2966, 2972, 2974-2975, 2977, 2979, 2981, 2987-2989, 2991-2992, 2998, 3000, 3003, 3006, 3009-3010, 3018, 3023-3024, 3026-3027, 3029-3030, 3035-3036, 3044, 3046-3047, 3050, 3053, 3056-3057, 3060, 3064, 3067-3069, 3073-3075, 3078, 3084-3085, 3090, 3093, 3095, 3098, 3102, 3104, 3108-3110, 3113-3118, 3120-3121, 3123, 3126, 3130-3131, 3138, 3140, 3152, 3156-3157, 3159, 3161, 3163, 3168, 3171, 3173, 3176, 3178-3179, 3196-3198, 3200, 3202, 3205, 3207, 3211, 3214, 3217-3218, 3228-3229, 3238-3240, 3244, 3249, 3254, 3257-3259, 3264, 3268, 3280, 3298, 3309, 3364, 3390, 3405, 3412, 3423, 3431, 3456, 3510, 3519, 3521, 3529, 3541-3542, 3545, 3549, 3555, 3558, 3563-3565, 3567, 3569, 3571, 3573-3574, 3576-3580, 3582-3583, 3585, 3588, 3590-3591, 3593-3600, 3602, 3604, 3611-3614, 3619, 3621, 3624, 3626-3627, 3629-3631, 3633, 3635, 3638-3641, 3643-3644, 3647-3648, 3650-3651, 3653, 3660, 3662, 3664, 3667-3668, 3670-3676, 3679, 3681-3682, 3693, 3698, 3703, 3708, 3716, 3718, 3721, 3727, 3738, 3743-3744, 3753, 3755, 3760, 3767-3768, 3778, 3785, 3787, 3790, 3799-3800, 3805-3807, 3809, 3813, 3816, 3820, 3828-3829, 3836, 3841, 3848, 3856, 3864-3865, 3891
C9	C9S00500, 504-505, 537-538, 543, 545-546, 550-551, 555, 560, 567-568, 574, 576-577, 583, 586, 588-593, 595, 597-598, 603-605, 607, 611-614, 618-620, 622-625, 627-628, 630-636, 638-643, 645-651, 653-656, 658-661, 664, 666, 668, 673-692, 694-714, 716-718, 720-727, 730, 732, 748-749, 751, 753-754

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*****Group 2*****
C7	C7S00849, 884, 892, 1062, 1097, 1124-1125, 1131, 1153-1155, 1158, 1160-1219, 1221-1252, 1254-1320, 1322-1329, 1331-1333, 1335-1336, 1338-1357, 1359-1375, 1377-1379, 1382-1383, 1385, 1387-1396, 1398, 1400-1405, 1407, 1409-1419, 1421-1433, 1435-1459, 1462-1463, 1466, 1469-1471, 1479, 1482-1483, 1485, 1488-1489, 1491, 1493, 1501, 1506, 1508, 1512-1513, 1515, 1517, 1519-1522, 1524-1525, 1527, 1529, 1531-1532, 1534-1536, 1538, 1541-1542, 1544-1546, 1548, 1550-1552, 1555-1557, 1560-1561, 1563, 1565, 1568-1569, 1572-1574, 1576, 1578, 1580, 1583-1584, 1587, 1602, 1606, 1610, 1613, 1615, 1643, 1647, 1651, 1653, 1656, 1665, 1676, 1684, 1692, 1726, 1734, 1737, 1741, 1746, 1768, 1772-1773, 1779, 1781, 1790, 1793, 1803, 1828, 1835, 1859, 1868, 1921, 1926, 1931, 1934-1935, 1938, 1956, 1967, 1981, 1996-1997, 2004, 2032, 2102, 2220, 2833, 3248, 3255, 3445
C9	C9S00501-00503, 506-507, 522-523, 527, 531, 534-536, 539-542, 544, 547-549, 552-554, 556-559, 561-566, 569-573, 578, 580-582, 584-585, 587, 594, 596, 599-602, 606, 608-610, 615-617, 621, 629, 652, 657, 693, 715, 735

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	6V8260	SEAL-O-RING
1	10R6350	PUMP GP-FUEL
1	2923739	TUBE AS-FUEL
1	2923740	TUBE AS-FUEL
*****Group 2*****
2	6V8260	SEAL-O-RING
1	10R6350	PUMP GP-FUEL
1	2923739	TUBE AS-FUEL
1	2923740	TUBE AS-FUEL

ACTION REQUIRED

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Group 1
If the engine serial number is listed, replace the high pressure fuel pump.

Group 2
Inspect fuel injection pump serial number located above the part number on the top of the fuel solenoid to see if pump needs replaced. (Refer to Image1)

Refer to Image2, Image3, Image4, and Image5 for serial numbers of affected fuel injection pumps. Replace pump, tube assembly, and o-rings listed in Parts Needed if installed pump serial number is listed in Image2, Image3, Image4, or Image 5.

Refer to RENR9707 Dissasembly & Assembly guide for proper replacement of fuel injection pump.

Note: 292-3740 Fuel As-Tube is for C9S Prefixes when ordering parts.

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Image1

Image2

Image3

Image4

Image5

OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 4.7-hour job for Group 1
Dealer to perform most economical repair. Description______________SMCS CODE________Hours Pump Replacement Engine Wash______________1251-074_________0.3 R&I Pump ________________1251-010_________4.1 Minor Road Test__________1000-530_________0.3 Exception maybe considered and claimed depending on chassis type.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 0.6-hour job for Group 2
Dealer to perform most economical repair. Option 1: 0.6 hours will be allowed to inspect the pump when the inspection determines pump serial number is not listed and pump replacement is not necessary. Description______________SMCS CODE________Hours Inspect Serial Number____1251-035_________0.6 Option 2 Pump Replacement: 4.7 Hours will be allowed to inspect and replace the pump when the inspection determines the pump serial number is listed and pump replacement is performed. Description______________SMCS CODE________Hours Engine Wash______________1251-074_________0.3 R&I Pump ________________1251-010_________4.1 Minor Road Test__________1000-530_________0.3 Exception maybe considered and claimed depending on chassis type.

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PARTS DISPOSITION

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***** U.S. and Canadian Dealers *****
NOTE: Make sure the outside of the shipping
container is marked PIXXXX.
Return all Fuel Injection Pumps that are replaced and a copy of the
claim to:
Caterpillar Inc.
Attn: PIXXXXX
BUILDING DD DOCK 8
ROUTE 29 OLD GALENA ROAD
MOSSIVILLE, IL 61552

***** All Other Dealers *****
Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
Attach. (1-Owner Notification)

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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IMPORTANT: SAFETY NOTICE

SAFETY ? RECALL FOR REPLACING THE FUEL PUMP

MODELS INVOLVED - C7 and C9 Truck Engines

Dear Caterpillar Product Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice is also in accordance with the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in trucks equipped with certain Caterpillar C7 & C9 engines.

A fuel pump failure will dilute the engine oil with fuel and may cause the turbocharger to fail and cause loss of throttle control and excessive smoke, both of which may result in a situation where a vehicle crash could occur. A new fuel pump will be installed on the engine. You will not be charged for the service performed.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own vehicle with this engine, please contact Caterpillar at this toll free number (800) 447-4986.

If the dealer is unable to have the repair made, please contact:

Caterpillar Inc.
PO Box 610
Mossville, IL 61552-610
Attn: Engine Products Division
Truck Engine Call Center
Telephone: (800) 447-4986

If you are unable to have the repair made within 60 days or without charge, you may submit a complaint to:

In the U.S.
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov

In Canada
Transport Canada
Road Safety and Motor Vehicle Regulation
Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851
Caterpillar Inc.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated -, 2007 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to do the inspection and have this service performed for your added safety and satisfaction.
Caterpillar Inc.

Identification #(s)
Attached to ________, 2007 Service Letter

Please refer the dealer to their Service Letter dated 31Aug2007 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 31Aug2007 Service Letter