19010-00650 BODY ASSY, INJECTI Denso Cross

05Dec2012
U-653
A-514
D-556
O-597
After Failure Only
PRODUCT SUPPORT PROGRAM FOR FOR REPLACING THE ELECTRONIC UNIT INJECTORS ON CERTIAN 777G OFF-HIGHWAY TRUCKS, 854K WHEEL DOZERS, 992K WHEEL LOADERS, AND D11T TRACK-TYPE TRACTORS
1290 1254 1713 PS52352
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 "PS52352" as the Part Numberand "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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.
TERMINATION DATE
31Dec2014
PROBLEM
The existing fuel injectors can experience injector failures due to injector body cracking. If the existing injector fails it can result in complaints of high oil levels due to excessive fuel dilution.
AFFECTED PRODUCT
Model Identification Number
777G RDR00102-00175
854K H8M00189-00195
992K 88000179-00209
D11T JEL00153-00269
JNS00130-00133
PARTS NEEDED
Qty
Part Number Description
2 1R1808 FILTER-LUBE
12 8S9191 BOLT
4 3460335 CLAMP-BAND
12 3594050 INJECTOR GP-FUEL
1 BULK_OIL DEO-ULS (See Action Required for Refill Qty)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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
If excessive fuel dilution of engine oil is found reference the following documents to determine the cause of fuel dilution.
Special Instruction, REHS3007,"Determining the Cause of Fuel Dilution of Engine Oil"
Troubleshooting, KENR9795, "C27 and C32 Engines for Caterpillar Built Machines"
Once an injector(s) has been identified as having a cracked/leaking injector body, replace the failed injector(s). Inspect the remaining good injector serial numbers with Cat ET, (Injector Serial Numbers = Injector trim file name, (ie 6Cxxxxxxxxxx.trm)). If the remaining injector serial numbers fall within the serial number range below, replace at the same time. Refer to Image 1 for the serial number
location on the top of the electronic unit injector.
Injector Serial Numbers
5C0018195245 - 5C0018588683
6C001930907B - 6C002200848C
If an injector failure occurs on either of the rear two cylinders (right and/or left hand bank) the exhaust piping going from the turbo to the CEM will have to be removed. 346-0335 Exhaust Clamp cannot be reused and MUST be replaced with a new clamp. Refer to REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for the proper installation and removal procedure. Refer to Image 2 for c