0204038 JOHNSON TERMINAL, Ring

15May2008
(Revised 20Mar2009)
U-262
A-214
D-211
O-234
Before/After
PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW FUEL INJECTORS ON CERTAIN C7 INDUSTRIAL ENGINES
1290 1251 1254 1713 PS42699
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 "PS42699" 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.
This Revised Service Letter replaces the 15May2008 (Revised 02Jul2008) Service Letter. Changes have been made to Termination Date.
TERMINATION DATE
31Mar2009
PROBLEM
The spool spring that is internal to the 295-1411 Fuel Injector is failing prematurely on certain C7 Industrial Engines. Symptoms of this type of failure are consistent with a flutter, skipping, or a fuel knock from the engine at higher speeds. This type of failure is generally a low hour failure.
Use the part hours that are on the fuel injector(s).
AFFECTED PRODUCT
Model Identification Number
C7 JRA00511-00519, 527, 532, 534, 536-538, 540, 547, 549-551, 554, 562, 567-569, 573, 575-578, 580, 583-584, 587-590, 620, 626, 652, 670-673, 679-681, 685, 687, 689, 695-696, 698-702, 707-709, 711, 720-743, 745, 747-748, 750-752, 767-769, 777-782, 784-785, 788-791, 794, 800-803, 808-815, 818-828, 830, 833-834, 836-842, 844, 848, 850-868, 870, 874-875, 878, 880, 882-883, 885-887, 889, 894, 896-898, 900, 902, 904-908, 910-918, 922, 926-928, 930-938, 940-944, 946, 953-957
JTF01910, 1930-1935, 1937-1940, 1942-1953, 1955-1959, 1965, 1970, 1972-1973, 1975-1987, 1989-2003, 2006, 2009-2013, 2016-2017, 2021-2022, 2026-2027, 2036, 2039-2040, 2063, 2067-2068, 2078-2079, 2082, 2084, 2087, 2089, 2092, 2094, 2100-2101, 2104, 2106-2108, 2113, 2116, 2118-2120, 2122, 2135, 2145-2149, 2151-2156, 2158-2162, 2188, 2191, 2194-2195, 2197-2199, 2201, 2203-2207, 2209-2212, 2218, 2220-2232, 2234-2235, 2237-2238, 2240, 2244-2246, 2259-2261, 2263, 2265-2267, 2271-2273, 2281-2282, 2286-2290, 2293-2296, 2299, 2301-2303, 2305-2308, 2311, 2313, 2322-2323, 2325, 2327, 2329, 2331-2332, 2335-2336, 2345-2348, 2350, 2352-2354, 2356, 2358-2360, 2363-2365, 2368-2374, 2377, 2379, 2381, 2389, 2391, 2394-2395, 2408-2411, 2414, 2416, 2425, 2430-2433, 2446-2448, 2450-2453, 2455-2456, 2458, 2461-2463, 2465-2466, 2469, 2476-2477, 2481, 2487-2490, 2492, 2496, 2498-2499, 2501, 2503, 2505, 2509, 2512, 2515, 2517, 2519-2520, 2528, 2530-2532, 2534, 2537-2541, 2543-2545, 2547-2553, 2555-2556, 2558-2563, 2565-2572, 2574-2575, 2577-2578, 2580-2583, 2585-2586, 2592, 2594, 2596-2599, 2602-2610, 2615, 2618, 2620, 2625-2626, 2628, 2631, 2633-2634, 2637-2639, 2643, 2645, 2648-2651, 2653-2656, 2658-2659, 2662-2665, 2667, 2670-2671, 2674, 2697-2698, 2700, 2702-2704, 2706-2707, 2710, 2712-2713, 2715-2716, 2719, 2722-2723, 2725, 2727, 2729, 2734-2740, 2742-2744, 2746, 2749-2751, 2754-2755, 2758, 2764-2765, 2768, 2771, 2773-2774, 2777-2779
PARTS NEEDED
Qty
Part Number Description
6 10R7225 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% 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
Take the following actions before or after a failure occurs on one or more injectors in any of the engines listed in this service letter.
- If one or more injectors fail it may be necessary to replace up to 6 injectors at the time of repair.
There will be situations when all 6 injectors do not have to be replaced. Refer to next paragraph to determine which injectors should be replaced.
- If an injector repair has previously been performed after approximately 01Oct07 on any of the listed engines, only the injectors that were not replaced at that time should be replaced. This should further be verified by comparing the injector serial numbers in the engine to a range of 3B115776403B to 3B11676551F9. Disregard the first and last two characters in the serial number (in t