09200-04950 PUMP ASSY, INJECTI Denso Cross

January 28, 2003
(Revised May 2003)
D-28
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPLACINGFAILED HEUI INJECTORS ON CERTAIN 3412E POWERED 773D OFF-HIGHWAY TRUCKS
1290 PS50599
This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50599" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This program can not be administeredunless the customer is using a 2 micron secondary fuel filter and usingeither the preferred CH-4, CG-4, or CF-4 Oil. This Revised Service Letter replacesthe January 28, 2003 Service Letter. Changes have been made to the MailCodes, and the Parts Needed.TERMINATION DATE
January 31, 2005PROBLEM
Replace failed HEUI injectors on certain 3412Epowered 773D Off-Highway Trucks. On certain machines, the 1388754,1388756,1590835, 1590836, 1747526, 1747527 or earlier Injectors may experiencea failure. This can be caused either by:
An individual injector failure, which can be repairedby replacing only the failed injector.
Or
Excessive injector poppet valve oil leakage onmultiple fuel injectors, which can be repaired by replacing a completeset of injectors and software (and possible FLS/FTS reset).
AFFECTED PRODUCT
Use the Machine S/N Range for the affected injectorbuild period in this service program as shown in the table below.
Model
Identification Number
Engine S/N Range
773D 7FZ73-227BGL73-111 IDX1-211IDX154-211PARTS NEEDED
A conversion involves the replacement of the fullset of injector and a software update. Individual injectors may still bereplaced. The troubleshooting tests (see attached rework procedure) shouldbe used in order to determine the repair method. Do not mix the injector part numbersfrom Table 1 with those found in Table 2. Verify that the software listed in Table2 is available before you start to convert the fuel system. The latestsoftware will be available through the Caterpillar Service InformationSystem.For replacement of individual failed injectorsincluding 1388754, 1388756, 1590835, 1590836, 1747526, 1747527 or earlierinjectors, use the following parts:
Table 1 ? Replacement of individual injectors
Qty
Part Number
Description
1 1747526 INJECTOR GP
2 1167221 SEAL
1 1167222 SEAL
1 9X7681 SEAL
1 3E6747 SEALFor replacement of complete set of failed injectors-
The parts required for complete update is notedin the list below.
Table 2 ? Conversion of full sets
Qty
Part Number
Description
1 per cylinder 1984752 INJECTOR GP
1 2143347 SOFTWARE
2 per cylinder 1167221 SEAL
1 per cylinder 1167222 SEAL
1 per cylinder 9X7681 SEAL
1 per cylinder 3E6747 SEAL* Old interlock code = 12, new interlockcode = 114. Old software part number = 1775372.ACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
If individual injectors are replaced on 3412E machines:
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-4000
0-48 mos 100%