0309023 JOHNSON SCREW, Inner housing

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 must be administered as soon as possible. When reporting the repair, use "PI3781" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3781" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
This Revised Service Letter replaces the June 21, 1995 Service Letter. Changes have been made to the Parts Needed.
Completion Date
December 31, 1995Termination Date
June 30, 1996Problem
The fuel injector tip may fail on certain 3406E Truck Engines.
Affected Product
Model & Identification Number
3406E (5EK371, 5EK378-380, 5EK382, 5EK403, 5EK405, 5EK435, 5EK453, 5EK455, 5EK461, 5EK485, 5EK486, 5EK500-502, 5EK509, 5EK510, 5EK515, 5EK516, 5EK518, 5EK527, 5EK538, 5EK544, 5EK555, 5EK570, 5EK593, 5EK602, 5EK609, 5EK619, 5EK634, 5EK639, 5EK642, 5EK649, 5EK658, 5EK660, 5EK664, 5EK670-672, 5EK674, 5EK676, 5EK677, 5EK685, 5EK686, 5EK691, 5EK698, 5EK710, 5EK714, 5EK726, 5EK731, 5EK732, 5EK734, 5EK743-746, 5EK750, 5EK752, 5EK756, 5EK767-770, 5EK772, 5EK777-874, 5EK876-878, 5EK880-883, 5EK885-905, 5EK907, 5EK908, 5EK912-919, 5EK921, 5EK931, 5EK933-1025, 5EK1028-1061, 5EK1064-1070, 5EK1072, 5EK1074-1098, 5EK1101-1118, 5EK1122-1140, 5EK1144-1155, 5EK1158-1190, 5EK1195-1208, 5EK1212-1220, 5EK1222-1252, 5EK1254-1297, 5EK1299, 5EK1300, 5EK1302, 5EK1303, 5EK1305, 5EK1307-1310, 5EK1313, 5EK1319, 5EK1322, 5EK1324, 5EK1326, 5EK1327, 5EK1329-1334, 5EK1336, 5EK1337, 5EK1340, 5EK1341, 5EK1343, 5EK1344, 5EK1346, 5EK1348-1372, 5EK1374-1379, 5EK1381-1384, 5EK1390-1425, 5EK1427-1433, 5EK1435-1451, 5EK1454-1459, 5EK1461, 5EK1463, 5EK1465, 5EK1468-1485, 5EK1489-1491, 5EK1493, 5EK1494, 5EK1496, 5EK1512-1517, 5EK1520-1522, 5EK1530, 5EK1531, 5EK1533, 5EK1539-1541, 5EK1543, 5EK1545-1562, 5EK1567, 5EK1569-1628, 5EK1630-1662, 5EK1664, 5EK1668-1680, 5EK1682-1693, 5EK1699-1716, 5EK1718-1746, 5EK1750, 5EK1753, 5EK1755-1811)
Parts Needed
Dealers will need to order parts for this Program.
6 - 0R4893 Injector Group (reman part number for 1171148) (used on 435 HP ratings 5EK371-1184, except 5EK988, 989, 1003, 1004, 1011, 1036, 1076)or6 - 0R4894 Injector Group (reman part number for 1188010) (used on 355, 375 and 435 HP ratings 5EK1185-1811, includes 5EK988, 989, 1003, 1004, 1011, 1036, 1076)or6 - 0R4895 Injector Group (reman part number for 1187929) (used on 410 HP ratings)Action Required
See attached rework procedure.
Service Claim Allowances
Cab Types
SC = Ford LN, L, LS, LA, Short ConventionalMC = Medium Hood ConventionalCV = Long Hood ConventionalCO = Cab OverParts Disposition
U.S. and Canadian Dealers
Return all fuel injectors that are removed from engines along with a copy of the claim and the Core Credit Request form (CCR) to:
Caterpillar Inc.
Attn: Jack Hoobler/PI3781
Service Claims Room
8201 N. University
Peoria, IL 61615
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
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. Inspect top of cylinder and injector bore for foreign material, such as an injector tip or an injector screen that may have fallen from removed injector.If a failure has occurred, also inspect the cylinder head and turbocharger for foreign material.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 "PI3781".