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Product: GENERATOR SET

Model: C9 GENERATOR SET SJB
Configuration: C9 Marine Generator Set SJB00001-UP POWERED BY C9 MARINE GS Engine

Service Letter
PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN C7
AND C9 MARINE AND GENSET ENGINES
Media Number -REBE5008-00 Publication Date -20/03/2009 Date Updated -20/03/2009
CONFIDENTIAL

REBE5008-00

20Mar2009

U-116
A-102
D-97
O-101
TM-6

After Failure PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL

Only INJECTORS ON CERTAIN C7 AND C9 MARINE AND GENSET
ENGINES

1290 1251 1254 1713 PS51640

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 "PS51640" 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:
The information supplied in this service letter may not be valid
after the termination date of this program. Do not perform the
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work outlined in this Service Letter after the termination date

without first contacting your Caterpillar product analyst.

TERMINATION DATE

31May2010

PROBLEM
The spool spring that is internal to the HEUI Fuel Injector may failing
prematurely on the product listed in this service letter. Symptoms of
this type of failure are consistent with a flutter, skipping, or a fuel
knock from the engine at higher speeds. This type of failure is
generally a low hour failure.

NOTE: Use the part hours that are on the fuel injector(s).

AFFECTED PRODUCT
Model Identification Number
*******Group 1*******
C7 C7D00343-00347, 351-387, 3001-3028

C7Z00287-00308, 311-324

M7A00100-00101, 108-109
*******Group 2*******
C9 C9A00713-00745, 747-759

SJB00373-00409, 411-420, 422-423, 425

*******Group 3*******
C9 C9E00527-00730, 733-739

X3R00685-00687, 694-804

X9X00903-00965, 3001-3064

X9Y00097-00099, 101, 103-119

Z9X00392-00394, 396, 398-402, 409-471, 484-487, 489-510

PARTS NEEDED

Part Number Description

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Qty

*******Group 1*******

6 3282587 INJECTOR GP-F -A

In order to allow equitable parts

availability to all participating dealers,
please limit your initial parts order to
not exceed 3% of dealership population.
This is an initial order recommendation
only, and the ultimate responsibility for
ordering the total number of parts needed
to satisfy the program lies with the
dealer.

*******Group 2*******

6 3282581 INJECTOR GP-F -A

In order to allow equitable parts

availability to all participating dealers,
please limit your initial parts order to
not exceed 3% of dealership population.
This is an initial order recommendation
only, and the ultimate responsibility for
ordering the total number of parts needed
to satisfy the program lies with the
dealer.

*******Group 3*******

6 3282580 INJECTOR GP-F -A

In order to allow equitable parts

availability to all participating dealers,
please limit your initial parts order to
not exceed 3% of dealership population.
This is an initial order recommendation
only, and the ultimate responsibility for
ordering the total number of parts needed
to satisfy the program lies with the
dealer.

ACTION REQUIRED
Take the following actions after a failure occurs on one or more
injectors in any of the machines listed in this service letter.

- If one or more injectors fail it may be necessary to replace up to 6

injectors at the time of repair.

NOTE: There will be situations when all 6 injectorsCaterpillar:

do not Confidential
have to be
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replaced. Refer to next paragraph to determine which injectors should

be replaced.

- If an injector repair has previously been performed after

approximately 01Oct07 on any of the listed machines, only the injectors
that were not replaced at that time should be replaced as part of this
program. This should further be verified by comparing the injector
serial numbers in the engine to a range of 3B115776403B to
3B11676551F9. Disregard the first and last two characters in the serial
number (in this case "3B" and "3B" in the first serial number and "3B"
and "F9" in the second serial number). The reason for verifying the
serial number range is due to a batch change of the internal part that
is failing. The change was made after serial number 3B11676551F9.

NOTE: Only injectors falling within the range of 11577640-11676551

should be replaced and claimed under this program.

- If the suspect injector can not be identified by using the automatic

cylinder cutout test use the two methods below.

- First, run a manual cylinder cutout test at a high engine speed with
some load on the engine. When the injector that has failed is cutout,
the sound of the engine should be more normal as opposed to the loud
knocking heard when the failed injector is active. The second method is
to unplug the wiring harness at the valve cover base that sends current
to the injector solenoids as well as the harness connection for the
injection actuation pressure sensor. By making these disconnections,
the fuel injectors will not fire and the HEUI pump will go to maximum
actuation pressure. Then remove the valve cover and crank the engine.
The injectors that have failed should expel more oil (from the HEUI
System) than those that are not failed.

-Refer to RENR9579 for removal/install procedure of the unit injector.

-The serial number of all injectors replaced in a machine covered under

this service letter must be documented in the claims story.

-If a sister engine is present in the vessel being serviced, it is

accepatble to replace all six injectors of the sister engine assuming
the engine serial number is included in this program and the injector
serial numbers are within the range outlined above.

SERVICE CLAIM ALLOWANCES

Product Caterpillar Dealer Suggested Customer Suggested

smu/age
whichever Labor Labor Labor
Parts % Parts % Parts %
comes first Hrs% Hrs% Hrs%

*******Group 1*******

0-1000 hrs, 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%

0-24 mo
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NOTE: This is a 4.0-hour job for Group 1

The serial number of any injector(s) replaced in a machine covered

under this service letter must be documented in the claims story.
Only injectors with serial numbers between 11577640-11676551 (see
action required for explanation on how to decode injector serial
number) will be allowed to be claimed under this service letter.

NOTE: If there has been a previous repair, part age will apply.
Retain a copy of the previous repair in the dealer's records for
audit purposes, and specify repair date and machine hours in the
"Additional Comments" section of the warranty claim.

Product Caterpillar Dealer Suggested Customer Suggested

smu/age
whichever Labor Labor Labor
Parts % Parts % Parts %
comes first Hrs% Hrs% Hrs%

*******Group 2*******

0-1000 hrs, 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%

0-24 mo

NOTE: This is a 4.0-hour job for Group 2

The serial number of any injector(s) replaced in a machine covered

under this service letter must be documented in the claims story.
Only injectors with serial numbers between 11577640-11676551 (see
action required for explanation on how to decode injector serial
number) will be allowed to be claimed under this service letter.

NOTE: If there has been a previous repair, part age will apply.
Retain a copy of the previous repair in the dealer's records for
audit purposes, and specify repair date and machine hours in the
"Additional Comments" section of the warranty claim.

Product Caterpillar Dealer Suggested Customer Suggested

smu/age
whichever Labor Labor Labor
Parts % Parts % Parts %
comes first Hrs% Hrs% Hrs%

*******Group 3*******

0-1000 hrs, 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%

0-24 mo

NOTE: This is a 4.0-hour job for Group 3

The serial number of any injector(s) replaced in a machine covered

under this service letter must be documented in the claims story.
Only injectors with serial numbers between 11577640-11676551 (see
action required for explanation on how to decode injector serial
number) will be allowed to be claimed under this service letter.
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NOTE: If there has been a previous repair, part age will apply.
Retain a copy of the previous repair in the dealer's records for
audit purposes, and specify repair date and machine hours in the
"Additional Comments" section of the warranty claim.

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

Copyright 1993 - 2018 Caterpillar Inc. Wed Apr 25 09:50:41 UTC+0300 2018
All Rights Reserved.
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