2003/12/01 Caterpillar

Engine:

C7 (S/N: KAL1-UP)

Truck Engine News SEBD6763, December 2003, "New Injectors and New Flash Files are Now in Production". Disregard this article. See the article that follows.

Description of Change: Some C7 truck engines may require all six injectors to be replaced if one of the injectors fail. The new injectors in production are not backward compatible with the former injectors.

Adaptable To: This change is effective in production with the following serial numbers:

• Low horsepower KAL07986-UP

• Medium horsepower KAL11871-UP

• High horsepower KAL12898-UP

The new injectors and the new flash files are adaptable to the serial numbers that are in Table 1, Table 2, and Table 3.

When you replace all six injectors you must install the injector trim files for each of the injectors. This will ensure proper engine performance and the correct emissions. Use Troubleshooting, "Injector Code - Calibrate" in order to install the injector trim codes. Use the following tables for the correct injector and for the correct flash files. Each engine rating corresponds with the correct flash files in the tables .

Note: Newer flash files may be available on Caterpillar Service Information System (SIS). Use the latest flash file that is listed on SIS for your engine rating.

Table 1

List of New Part numbers for the Injectors and the Flash Files for the Low Horsepower
Affected Serial Number Range	Engine Rating		New Part Number for Injector	Former Part Number for Injector	New Injector with Seals	Former Injector with Seals	Interlock Code	Flash Files for the New Injectors
	Power	Torque
S/N:KAL1-07985	141 kW (190 hp)	705 N·m (520 lb ft)	241-3238	233-3536	243-4502	236-0973	25	247-4632
S/N:KAL1-07985	156 kW (210 hp)	705 N·m (520 lb ft)	241-3238	233-3536	243-4502	236-0973	26	247-4631
S/N:KAL1-07985	156 kW (210 hp)	820 N·m (605 lb ft)	241-3238	233-3536	243-4502	236-0973	27	247-4630

Table 2

List of New Part number for injectors and New Part Numbers for the Flash Files for the Medium Horsepower Ratings
Affected Serial Number Range	Engine ratings		New Part Number for Injector	Former Part Number for Injector	New Injector with Seals	Former Injector with Seals	Interlock Code	Flash Files for the New Injector
	Power	Torque
S/N:KAL1-11870	171 kW (230 hp)	732 N·m (540 lb ft)	241-3239	236-6011	243-4503	238-9808	28	247-4629
S/N:KAL1-11870	171 kW (230 hp)	894 N·m (660 lb ft)	241-3239	236-6011	243-4503	238-9808	29	247-4628
S/N:KAL1-11870	186 kW (250 hp)	894 N·m (660 lb ft)	241-3239	236-6011	243-4503	238-9808	30	247-4627

Table 3

List of New Part number for Injectors and New Part Numbers for Flash Files for the High Horsepower Ratings
Affected Serial Number Range	Engine Ratings		New Part Number for Injector	Former Part Number for Injector	New Injector with Seals	Former Injector with Seals	Interlock Code	Flash Files for the New Injector
	Power	Torque
S/N:KAL1-12897	186 kW (250 hp)	1084 N·m (800 lb ft)	238-8091	233-3535	241-3400	236-0974	41	247-4626
S/N:KAL1-12897	205 kW (275 hp)	1084 N·m (800 lb ft)	238-8091	233-3535	241-3400	236-0974	42	247-4625
S/N:KAL1-12897	205 kW (275 hp)	1084 N·m (800 lb ft) ER	238-8091	233-3535	241-3400	236-0974	46	247-4624
S/N:KAL1-12897	205 kW (275 hp)	1166 N·m (860 lb ft)	238-8091	233-3535	241-3400	236-0974	43	247-4623
S/N:KAL1-12897	205 kW (275 hp)	1166 N·m (860 lb ft) ER	238-8091	233-3535	241-3400	236-0974	47	247-4622
S/N:KAL1-12897	223 kW (300 hp)	1084 N·m (800 lb ft)	238-8091	233-3535	241-3400	236-0974	44	247-4620
S/N:KAL1-12897	223 kW (300 hp)	1084 N·m (800 lb ft) ER	238-8091	233-3535	241-3400	236-0974	48	247-4619
S/N:KAL1-12897	223 kW (300 hp)	1166 N·m (860 lb ft)	238-8091	233-3535	241-3400	236-0974	45	247-4618
S/N:KAL1-12897	223 kW (300 hp)	1166 N·m (860 lb ft) ER	238-8091	233-3535	241-3400	236-0974	49	247-4617
S/N:KAL1-12897	246 kW (330 hp)	1166 N·m (860 lb ft) ER	238-8091	233-3535	241-3400	236-0974	50	247-4616
S/N:KAL1-12897	246 kW (330 hp)	1166 N·m (860 lb ft) RV	238-8091	233-3535	241-3400	236-0974	51	248-2319