PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C7 AND C9 ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C7 AND C9 ENGINES

Usage:

SEBE8859-02

July 23, 2004
(Revised August 2005)
U-223
A-153
D-170
O-190
TT-18

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT ON CERTAIN C7 AND C9 ENGINES
1250		PI30681

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30681" 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 "PI30681" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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: The Revised Service Letter replaces the December, 2004 Service Letter. Changes have been made to the Termination Date.

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COMPLETION DATE	TERMINATION DATE
January 31, 2005	October 31, 2005

PROBLEM

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

AFFECTED PRODUCT

***Group 1***

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Model	Identification Number
C7	KAL01098-32136

***Group 2***

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Model

Identification Number

9DG594-1442

MTB105-1051

CSN406-649

PARTS NEEDED

***Group 1***

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Qty	Part Number	Description
1	2544334	CHECK VALVE KIT
1	10R1308	HEUI PUMP

***Group 2***

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Qty	Part Number	Description
1	2544334	CHECK VALVE KIT
1	10R1307	HEUI PUMP

ACTION REQUIRED

Notice: Failure to install the "Service Bolt", included in check valve kit, prior to removing fuel transfer pump mounting bolts WILL CAUSE THE HEUI PUMP TO SEPARATE AND FAIL! Follow Special instructions REHS2253 carefully!

Illustration 1

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

C7 2285898 HEUI pump

C9 2285896 HEUI pump

If HEUI pump part number is not listed above?STOP.

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

C7 8980054776 - 8980100294

C9 8960058125 ? 8960112590

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)

If HEUI pump is stamped "CV"?STOP

Install the 2544334 Check Valve Kit using the rework procedure in Special Instruction REHS2253.

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".

OWNER NOTIFICATION

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
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. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

**Labor Hour/Supplement Breakdown by Cab Type

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SMCS Code	SC	MC	CV	CO	BU	Description
7751-040	0.4	0.4	0.4	0.4	0.4	Inspect
7751-522-CV	2.8	2.4	2.4	2.4	2.8	Replace Check Valve

PARTS DISPOSITION

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

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

Attach. (1-Owner Notification)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY ? PRODUCT IMPROVEMENT PROGRAM FOR INSTALLATION OF A CHECK VALVE KIT

MODELS INVOLVED - CERTAIN C7 AND C9 ENGINES

Dear Caterpillar Product Owner:

New check valve assemblies for the fuel rail oil pump needs to be installed on the products listed below. Failure to have this update performed may result in hard starting and/or rough running.

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 July 23, 2004 when scheduling this service. You will not be charged for the service performed.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to July 23, 2004 Service Letter