101603-7711 ZEXEL F 019 Z20 471 BOSCH INJECTION-PUMP ASSEMBLY f019z20471 1016037711 8943930791

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.
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 "PS0852" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the June 22, 1995 (Revised July 1996) Service Letter. Changes have been made to the TERMINATION DATE.
Termination Date
June 30, 1997Problem
The fuel injector tip may fail on certain 3406E Truck Engines.
Affected Product
Model & Identification Number
3406E (5EK1812-14203)
Parts Needed
6 - 0R4893 Injector Group (reman part number for 1171148) (used on 435-5EK1-1820 HP ratings)or6 - 0R4894 Injector Group (reman part number for 1188010) (used on 355-5EK1-1820, 375-5EK1-1820, 375-5EK1-1820, 435-5EK1821-Up, 455, and 475 HP ratings)or6 - 0R4895 Injector Group (reman part number for 1187929) (used on 355-5EK1821-Up, 375-5EK1821-Up, and 410 HP ratings)Action Required
See attached rework procedure.
Service Claim Allowances
Labor should be claimed in accordance with labor times listed in the 3406E Time Requirement Guide.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(Rework Procedure)Rework Procedure
1. Remove the necessary air piping, air cleaners, valve covers, Jake Brakes, and rocker arm assemblies.2. Before removing fuel injectors from engine, be sure to drain fuel from fuel system. The recommended procedure is to blow compressed air through system via the fuel filter air bleed cap. Remove the fuel injectors from the engine. Immediately clean off excess engine oil and place the fuel injectors in individual clean plastic bags. Use care to prevent dirt from entering the fuel passages in the side of the injector.3. Wrap each injector individually with padding. Be sure to provide adequate padding around the injectors to prevent damage to the electrical terminals and nozzle during shipment. Pack the injectors in a sturdy box for immediate shipment back to Caterpillar. (See PARTS DISPOSITION.)4. If the tip of the injector is cracked, inspect top of cylinder and injector bore for foreign material. If the tip is missing, inspect the cylinder head and turbocharger for foreign material. Also inspect the injector for a screen that may have fallen from the removed injector.5. Lubricate the two larger o-ring seals with engine oil and install the injectors. Tighten the injector hold down bolt to a torque of 55 N m (41 ft lb).6. Adjust the valves, injectors, and Jake Brakes if so equipped. Complete the assembly.7. Prime the fuel system as described in Systems Operation Testing and Adjusting, SENR5578, page 69, "Fuel Priming Procedure".8. Stamp the engine block with the letters "PS0852".