INJECTOR GP-FUEL 3920227 - Caterpillar

This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4756" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This PSP covers retrofit of air intake line only. It does not cover Air Compressor replacement (no contingent damaged parts allowed).
If the customer prefers to retain the boosted air supply, which requires the Inlet Regulating Valve (IRV), proper service of the IRV is required every 30,000 miles.
This Revised Service Letter replaces the April 5, 1999 Service Letter. Changes have been made to the Action Required.
Termination Date
April 30, 2000Problem
Four cylinder air compressors with air supplied from the engine intake manifold has an inlet regulating valve (IRV) which requires frequent maintenance. If not properly maintained, the IRV can fail which may result in an air compressor failure.
Affected Product
Model & Identification Number
3176B (9CK5053-Up)
C-10 (2PN1095-Up 8YS500-5193 )
C-12 (1YN1278-Up 9NS500-13662 )
3406E (5EK1-Up 6TS1-Up 1LW1-Up 5DS1-Up )
Parts Needed
*8 - 3E7424 CLAMP-HOSE1 - 5N7444 HOSE1 - 9S8008 PLUG-O-RING1 - 6V5063 SEAL-O RING1 - 7W1890 ELBOW-90 DEG2 - 7X7958 CLAMP-HOSE1 - 532313 CONNECTOR*2 - 1051175 HOSE1 - 1666339 PIPE AS-AIR*Use as needed (see instructions)Action Required
1. Remove the IRV, rubber air hose, clamps and fittings that connect the air compressor inlet manifold with the engine air inlet manifold.2. Install pipe plug 9S8008 and 6V5063 o-ring seal into engineintake manifold boost port.3. Locate an inlet air supply location between the air cleaner and turbocharger (as close to the air cleaner as possible). Install the 6" diameter 166-6339 Pipe assembly (cut to length and remove burrs) using the two 105-1175 Hoses and the eight 3E7424 Clamps (double clamp). Use existing 6" Air System hoses (pipes) and clamps if possible. If not possible, use 1051175 Hoses and 3E7424 Clamps.
4. Install the 7W1890 Elbow or 053-2313 Nipple (as required) in the air compressor inlet manifold.5. Install the 1" inside dia rubber hose 5N7444 (cut to proper length) in position between the fitting of the air compressor air inlet manifold and the 1" boss on the 6" diameter 166-6339 Pipe Assembly.6. Use the 7X7958 Hose Clamps to secure the hose to the fitting on the air compressor air inlet manifold and the 1" boss on the 6" inside dia 166-6339 Pipe Assembly boss.7. To retrofit a 5" air supply, use two 4w7731 Hose Reducers (in place of the two 105-1175 Hoses) and two 8T4987 Clamps (in place of four 3E7424 Clamps).Service Claim Allowances
This is a 2.8-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.