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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

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

    2. 2323911 HEUI pump 232-3912 HEUI pump
    2044944 HEUI pump 204-4945 HEUI pump
  2. Verify s/n on HEUI pump is in the following range. (See Illustration 1)

    3. 9440054815 ? 9440075582 9450054950 - 9450076214
    9110085776 ? 9110099469 9120076215 ? 9120111408

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

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


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

  4. 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
 
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.

PARTS DISPOSITION

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

Caterpillar Information System:

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PRODUCT SUPPORT PROGRAM FOR REPLACING THE THROTTLE CABLE THAT MAY BIND ON CERTAIN 416D, 420D, 420D IT, 430D, AND 430D IT BACKHOE LOADERS PRODUCT SUPPORT PROGRAM FOR REPLACING THE THROTTLE CABLE THAT MAY BIND ON CERTAIN 416D, 420D, 420D IT, 430D, AND 430D IT BACKHOE LOADERS
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PRODUCT SUPPORT PROGRAM FOR REPLACING THE TOP PISTON RING ON CERTAIN 3126 ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE TOP PISTON RING ON CERTAIN 3126 ENGINES
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PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING 1053025, 1053030, AND 1017368 VALVES IN PARTS STOCK AND REMOVING THEM IF NECESSARY PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING 1053025, 1053030, AND 1017368 VALVES IN PARTS STOCK AND REMOVING THEM IF NECESSARY
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