0513663 JOHNSON CONNECTOR

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PSP FOR FUEL TRANSFER PUMP VALVES; 3406B TRUCK,MARINE, INDUSTRIAL, GEN SET ENGINES; 16G MOTOR GRADERS; 245 EXCAVATORS & F RONT SHOVELS; 824C TRACTORS, 825C, 826C COMPACTORS; 980C LOADERS - PS4021 - MAILED US, CANADA, CFEL AND COSA
  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.
PRODUCT SUPPORT PROGRAM FOR FUEL TRANSFER PUMP VALVES; 3406B TRUCK, MARINE, INDUSTRIAL, GENERATOR SET ENGINES; 16G MOTOR GRADERS; 245 EXCAVATORS AND FRONT SHOVELS; 824C TRACTORS, 825C, 826C COMPACTORS; 980C LOADERS, 1256, PS4021 U-81 C-65 E-55 O-52 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4021" as Part Number and "7755" as Group Number. Although products in the field are to be administered as described above, dealers should purge parts stock immediately. A Service Letter similar to this one has been sent to all TEPS Dealers. Termination Date
October 31, 1986.
Problem
The fuel transfer pump on the above engines has three 1W6182 or 7W402 Valve Assemblies. The one valve in the piston can break in extremely cold weather. Some damage can also occur to the other valve assemblies. This problem has been reported mainly in cold weather applications. A new valve with improved cold temperature capability is now used in the piston and at the other two locations in the pump. These valves are directly adaptable to earlier engines.
Affected Product
Some of the following vehicles contain the 3406 Engine with the former scroll fuel system and are not in this Program. Model Identification/Serial Number 3406B Truck Engine 7FB1-41754 3406B Marine Engine 4TB1-641 3406B Industrial Engine 6TB1-2539 3406B Generator Set 2WB1-2692 16G Motor Grader 93U2284-2523 245 Excavator 95V1084-1193 94L525-751 245 Front Shovel 82X618-633 84X686-857 621B Tractor 2GB124 45P3521-3827 623B Tractor 46P1957, 1971-2198 627B Tractor 14S1188, 1191, 1212, 1220, 1237, 1252, 1253, 1267, 1277 15S1729 824C Tractor 85X958-1174 825C Compactor 86X634-730 826C Compactor 87X338-559 980C Loader 63X4923-6349 2EB367-379 13B373-588
Parts Needed
1 - 7C396 Spacer 1 - 6J2419 Seal 1 - 3D2824 Seal 1 - 5P8215 Seal 1 - 3D2898 Seal 3 - 7W8412 Valve As. 1 - 6F6672 Seal 1 - 4J8997 Seal
Action Required
Remove all 1W6182 or 7W402 Valve Assemblies from parts stocks. Do not use any former 4W6908 Seals or 7W801 Spacers in 3406B Engine applications. To prepare for this Program, dealers should first rebuild a few transfer pumps to be used as exchange pumps. Install a transfer pump that has all the new parts on the affected product. It is recommended that this repair be made before failure on engines expected to operate in temperatures below -12 deg. C (10 deg. F). Engines operating in temperatures above this are unlikely to fail. Be sure to use the 7C396 Spacer (Blue) with the new valve. The new valve is thinner and requires the new, thicker spacer. Before work is started, see if an "X" is stamped on the outer rear face of the transfer pump mounting flange near the short mounting bolt. This identification means that the pump has been reworked at the factory or by another dealer. Rework 1W1700 Transfer Pump Groups in your parts stock and stamp an "X" on the flange. 1W1700 Pumps in the parts distribution system that have a date code of "9-85" or later contain the latest parts. WARRANTY ALLOWANCES * Caterpillar Dealer Suggested Customer Suggested Parts Labor Hr Parts Labor Hr Parts Labor Hr (D/N) (Cost) (C/L) (Sell) 100% 1 0 0 0 0 * If OEM, parts are at C/L and labor at the sell rate. This is a 0.5 hour job, but includes 0.5 hours for rebuilding the pump. Because of the low dollar value of the parts and labor for each engine to be modified, the following claim procedure can be used for this Program. A consolidated claim may be submitted for up to ten reworked engines. Fill out the heading information for one PIN (S/N) as you normally would for a PSP claim. List additional PIN's (S/N) with hours or miles at the time of rework in the "Comment Section" of the claim. Make a SIMS report for each PIN (S/N) on the claim and indicate in the claim comments "SIMS Entry Made For ALL PIN's (S/N)". In the "Other Expenses" section of the claim, list total