101402-2200 ZEXEL 9 400 613 861 BOSCH INJECTION-PUMP ASSEMBLY 9400613861 1014022200 220203590a

This Program must be administered either before or after failure.In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS42405" as the Part Numberand "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.If administered after failure, use "96" as the Warranty Claim Description Code, and "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
31May2009
PROBLEM
The 207-5248 Injector Rock Arms used in some C18 Marine Engine applications have been found to crack and break through the adjusting screw threads at the nose of the arm.
AFFECTED PRODUCT
Model Identification Number
C18 CKH00359, 426, 741, 744-745, 748-749, 1542-1543, 1594, 1641-1642, 1763-1764, 1805, 2053
PARTS NEEDED
Qty
Part Number Description
6 10R4704 ARM AS-UI ROCKER
ACTION REQUIRED
Refer to attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-2000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
For the following units listed remove (6) 207-5248 Injector Rocker Arms, and replace with (6) 10R4704 Injector Rocker Arms.
For proper Disassembly & Assembly instructions of the injector rocker arms please refer to the following Publications in SIS Web. (SENR9832 Testing & Adjusting - Finding Top Dead Center Position for No. 1 Piston), (SENR9832 Testing & Adjusting - Electronic Unit Injector Adjusting & Setting), and (SENR9832 Testing & Adjusting - Engine Valve Lash Inspect/Adjust).
Note: It is important that while installing the 10R4704 Injector Rocker Arms, that the engine is in the proper position (Top Dead Center and 180 degrees out) so the Injector Rocker Arms are properly adjusted and set. It is also important that during the installation of the Injector Rocker Arms that the Exhaust Valve, and Intake Valve lash settings be inspected and if needed reset to factory specifications.
Note: During the rework process please inspect the 6I-0901 Rocker Arm Shafts for any signs of misalignment of the stud mounting holes, wear, damage, fretting etc. If damage is found to the shaft or if fretting or damage is found with any of the through bolt/stud mounting holes, the shaft is to be replaced, and reported against this service letter as contingent damage.