19010-01800 BODY ASSY, INJECTI Denso Cross

August 3, 2002
(Revised October 2003)
U-191
A-136
AU-145
S-145
H-143
O-157
Afterfailure only PRODUCT SUPPORT PROGRAM FOR REPLACINGFAILED HEUI INJECTORS ON CERTAIN 3408E AND 3412E POWERED 836 COMPACTORS;834B AND 844 WHEEL DOZERS; 988F AND 990 WHEEL LOADERS; 24H MOTOR GRADERS;5110B EXCAVATORS; 631E, 633E, 637E, 651E, AND 657E SCRAPERS; 769D, 771D,773D, AND 775D OFF HIGHWAY TRUCKS; D9R AND D10R TRACK-TYPE TRACTORS; PM-565BASPHALT PROFILERS; 69D, AD40/AE40, AD45/AE40, AND 73D ELPHINSTONE MACHINES
1290 PS50424
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 "PS50424" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. If claim is based on partshours, the parts start date and parts hours must be included in the claimstory. 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 program replaces Product SupportProgram PS5615. This Revised Service Letter replacesthe August 3, 2002 (Revised June 2003) Service Letter. Changes have beenmade to the Affected Product.TERMINATION DATE
August 31, 2004PROBLEM
On certain machines, the 1313098, 1388754, 1388755,1388756, 1590835, 1590838, 1747526, 1747527, 1757528, 0R0815, 0R8624, 0R9420or earlier Injectors may experience a failure. This can be caused eitherby:1.) An individual injector failure, whichcan be repaired by replacing only the failed injectorOr2.) Excessive injector poppet valve oil leakageon multiple fuel injectors, which can be repaired by replacing a completeset of injectors and software (and possible FLS/FTS reset).AFFECTED PRODUCT
Use the Engine S/N Range for the affected Injectorbuild period in this service program as shown in the table below. The correspondingapproximate model S/N ranges are only shown for reference. Each machineis eligible for the updated injector sets with software only once. If anengine within the affected product range previously had a Tier 1 product10R0964 or 1984752 Injector set installed (for 99C or 80M engines), ora Tier 2 product 10R0969 or 2061217 Injector set installed (for 5XD or5JJ engines), it is not eligible for this program.
Model Model S/N Range Engine S/N Range
834B 7BR1-737 99C1-7377
836 7FR1-478 99C1-7377
988F 2ZR1-2466 99C1-7319
631E 1AB1640-2111
1NB1390-1498 99C1-7369
631G AWK1-272 5XD1-843
633E 2PS290-319 99C1-7371
637E 1FB660-1001 99C1-7371
637G AXT1-316 5XD1-843
657E 6PR1-114
7KR1-329 99C1-7370
769D 5SS1-6525TR1-1054BBB1-136 99C1-73805XD1-837
771D 6YS1-4416JR1-309BCA1-135 99C1-73805XD1-837
69D 9SS169-180
9XS1-80 99C1-7390
AD40/AE40 1YZ1-2391ZZ1-3582ZS25, 31-34, 58-64, 73-76, 91-94,124-127 99C1-7404
AD45/AE40 BLW181-183BKZ181-196 99C1-7418
D9R 7TL557-1409
8BL830-1514
ABK1-708
ACL1-853 99C1-7375
5XD1-843
PM-565 3TK113-123 99C1-2500
PM-565B 8GS1-225