09300-05093 PUMP ASSY, INJECTI Denso Cross

November 17, 2001
(Revised July 2003)
U-316
A-220
AU-210
S-161
H-119
O-241
TT-10
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE FUEL INJECTOR ONLY AFTER AN INJECTOR TIP FAILURE IN CERTAIN C-10, C-12,C-15, C-16, AND 3406E TRUCK ENGINES
1254 PS50338
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 "PS50338" 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 Revised Service Letter replacesthe November 17, 2001 (Revised Janu 2003) Service Letter. Changes havebeen made to Termination Date.TERMINATION DATE
December 31, 2003PROBLEM
The fuel injector tip may fail on certain C-10,C-12, C-15, C-16 and 3406E Truck Engines.AFFECTED PRODUCT
Model Identification Number
C-10 3CS4110-17279
C-12 2KS358-22375,ONLY IF Failed Injector is 14703732KS22376-56788
C-15 6NZ1-29748
C-16 7CZ1-1609
3406E 2WS23702-427981MM1-1488PARTS NEEDED
Qty
Part Number Description
C-10 (Only 3CS)
1 0R8780 Injector Group (RemanPart number for 1611708 Injector Group)
C-12 (Only 2KS)
1 0R8773 Injector Group (RemanPart number for 1470373 Injector Group)
3406E/C-15/C-16 (2WS,1MM,6NZ,& 7CZ)
1 0R9256 Injector Group (RemanPart number for 1408951/1592631 used on
355 HP ? 375/435 M/T HP,410HP Field Uprate, & 450 HP Field Uprate)
1 0R9257 Injector Group (RemanPart number for 1408993/1592479 used on
435 HP-600 HP, Excluding 450HP Field Uprate)ACTION REQUIRED
C-10 and C-12
Replace the failed injector and contingent damage.3406E/C-15/C-16
If the failure is in cylinder #1, replace onlythe failed injector and any contingent damage.If a failure occurs in any cylinder other thancylinder #1, replace the failed injector, any contingent damage and theinjector in cylinder #1 if that injector is part number 1592631 or 1592479and the injector serial number is below 1476551.C-10, C-12, 3406E, C-15, and C-16
Remove the necessary air piping, air cleaners,valve covers, Jake Brakes, and rocker arm assemblies.
Before removing the fuel injector/s from engine,be sure to drain fuel from fuel system. The recommended procedure is toblow compressed air through system via the fuel filter air bleed cap. Removethe fuel injector/s from the engine.
Mark the cylinder number on the failed injector.
Replace damaged engine components as a resultof the injector tip failure.
Lubricate the two larger o-ring seals with engineoil and install the injector/s. Tighten the injector hold down bolt accordingto the torque value found in Service Manual.
Record Injector Trim code Prior toinstalling New Injector.
Adjust the valves, injector, and Jake Brakes ifso equipped. Complete the assembly.
Enter the Injector trim code from the injectorinto the ECM.
Prime the fuel system and start the engine.
Include the cylinder number and serial numberof the failed injector in the claims story.
SERVICE CLAIM ALLOWANCES
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-300,0000-36 mos 100% 100% 0 0 0