106672-3479 ZEXEL 9 400 617 089 BOSCH INJECTION-PUMP ASSEMBLY 9400617089 1066723479 220006505a

TERMINATION DATE
30Sep2014
PROBLEM
The existing fuel injectors can experience solenoid valve poppet seizures or poppet binding within injector body due to excessive thermal expansion. If the existing fuel injector fails it can result in complaints of misfire and/or low power.
AFFECTED PRODUCT
Model Identification Number
AD55B JNW00101-00151, 153-155, 157-166, 168-199, 201-244, 246, 248-269, 272-275, 60250
PARTS NEEDED
Qty
Part Number Description
12 8S9191 BOLT
24 3565212 BOLT-12 POINT HD
12 3740751 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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
A fuel injector is considered failed if the following troubleshooting Step 1 and Step 2 are completed and the problem is not resolved. Troubleshooting is not cover by this letter.
1. Ensure ECM software is current.
2. Perform the following procedures:
KENR5424 ? Troubleshooting
SENR9937 - Electronic Unit Injector ? Adjust
SENR9937 - Electronic Unit Injector - Test
3. Replace injector(s) as required.
If one or more injectors fail replace all injectors at the time of repair.
Refer to Disassembly and Assembly, RENR9217 for the removal and installation procedure of the unit injector.
8S-9191 Injector Hold Down Bolt must be replaced. Ensure that the proper torque is achieved, 55 +/- 10 Nm (41 +/- 7 lb ft).
356-5212 Rocker Arm Shaft Hold Down Bolts must be replaced. Ensure that proper torque procedure is adhered to.
1. Position rocker arm shaft assembly (4) , valve rocker arms (3) , and electronic unit injector rocker arms (1) as a unit with 124-2946 Lifting Bracket on the cylinder head.
Note: Apply clean engine oil to the underside of the bolt heads prior to installation.
2. Install bolts (2) and tighten to a torque of 55 +/- 5 Nm (41 +/- 4 lb ft). Tighten bolts (2) again to a torque of 55 +/- 5 Nm (41 +/- 4 lb ft). Turn bolts (2) for an additional 60 +/- 5 degrees. Tighten the bolts in the following sequence: 2, 3, 1, 4.
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SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-18 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 16.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.