101603-7400 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1016037400 1156026590

PROBLEM
The fuel inlet check valves, on the fuel injection pump, may fail on certain C6.6 Industrial Engines that are installed in specific OEM Applications. A failure of the inlet check valves could result in any of the following symptoms: failure to start, prevention of the engine from achieving full power, or a de-rate of the engine.
Before any repair is carried out, ensure the appropriate trouble shooting steps have been followed and carried out.
AFFECTED PRODUCT
Model Identification Number
C6.6 TIER 3 66605372, 5675-5678, 5680-5683, 5685-5686, 5688-5695, 5697-5699, 5701-5703, 5718, 5720, 5722-5723, 5726, 5728-5729, 5733, 5735-5737, 5739, 5741-5749, 5751-5754, 5756, 5758-5771, 6007-6008, 6010, 6012-6013, 6015, 6018, 6020-6021, 6024, 6438, 7207-7209, 7211-7215, 7222-7225, 7227-7231, 7235, 7237-7239, 7268-7271, 7273-7275, 7277, 7280-7281, 7284-7287, 7428, 9732, 9747, 9749-9751, 9753-9754, 9756-9760, 9765, 9790-9791, 9794-9800, 9804-9807, 9809, 9823-9826, 9828, 9830-9837, 9839, 9842, 9877, 9879-9884, 9886-9891, 9893-9894, 9897-9898, 9901-9902, 9931, 9933-9937, 9940-9943, 9945, 9947, 9950, 9952-9954, 9959-9960, 10000, 10003, 10005, 10009-10010, 10012-10013, 10015-10016, 10018-10023, 10116, 10119-10125, 10129, 10131-10133, 10135-10136, 10138-10141, 10144-10145, 10147-10149
PARTS NEEDED
Qty
Part Number Description
1 1113423 WASHER
1 2258019 GASKET-PUMP-HSG
6 2323149 WASHER-SEALING
1 2782285 ELBOW
1 2784138 PROTECTION KT
1 3368180 TUBE FUEL-INJ
1 3495736 PUMP GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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
Replace the existing fuel injection pump group with a new 349-5736 fuel injection pump group.
Refer to appropriate service manuals as necessary.
Rework Procedure:
1. Remove machine parts as necessary to gain sufficient access to the engine.
2. Remove existing fuel injection pump and replace it with a new 349-5736 fuel injection pump group. Refer to the Disassembly & Assembly Instruction RENR9722 Fuel Injection Pump - Remove and Install. If a compression fitting is used to connect the pipe from the filter to the pump a new nut and olive will be required. This is part of the elbow assembly 278-2285, remove one of the nuts and olives from the elbow and use this to reconnect the pipe to the new pump, the rest of the elbow can be discarded.
3. Ensure that all the warnings and notices are adhered to and safety practices are followed. Ensure that the protection caps are used during this operation to prevent issues with contamination.
4. Install all parts that were removed to gain access to the engine.
5. Check for leaks and repair as necessary.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.