PRIORITY - NEW SPRINGS NEED TO BE INSTALLED IN THE UNIT INJECTORS ON CERTAIN 3606, 3608, 3612 AND 3616 ENGINES - PI3 396 - MAILED US, CANADA, CACO, COFA, LIMITED BRAZIL, CFEL, COSA Caterpillar

U-75
A-53
AU-49
B-12.2
E-38.1
O-53.1
PRIORITY
parts stock  1290  PI3396
COMPLETION DATE  

October 31, 1989 April 30, 1990

The springs in the unit injectors on certain 3606, 3608, 3612, and 3616
Engines may fail and cause unscheduled down time. A spring failure may
cause damage to a pushrod or rocker arm.

Model Identification Number
3606 8RB1-293, 296, 297, 314-350, 352, 354,
3608 6MC1-242, 248-250, 251, 253-275, 277-280
5PG1-3
3612 9RC14, 15, 18-47, 52, 53, 57, 58
3616 1PD1-28

Dealers will need to order parts for this Program.
***** Parts Stock *****
1 - 7E5404 Spring (1 for each 7C7445 or 7C3854 Injector in the
customer or dealer parts stock)
***** Affected Product *****
1 - 7E5404 Spring (1 per cylinder)
1 - 7W1990 Retainer (use as required)
1 - 7N9463 Keeper (use as required)

***** Parts Stock *****
Use the attached procedure and tool list for the Affected Product as a
guide. Replace the existing spring in each 7C7445 or 7C3854 Injector in
customer or dealer parts stock with a new 7E5404 Spring.
***** Affected Product *****
See the attached procedure.

Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(C/L) (Sell)  (C/L) (Sell)
***** 3606 Engines *****
100% 6 0 0  0 0
***** 3608 Engines *****
100% 8 0 0  0 0
***** 3612 Engines *****
100% 12 0 0  0 0
***** 3616 Engines *****
100% 16 0 0  0 0
***** Parts Stock Injectors *****
100% .5 0 0  0 0
NOTE: This is a 1-hour job per cylinder in the Affected Product
and a .5-hour job per injector for injectors in customer or
dealer parts stock. Submit one claim for replacing the
spring in all parts stock injectors.

Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach. (1-Spring Replacement Procedure)
(2-Fabricated Tool List)
Spring Replacement Procedure
1. Remove the rocker arm assembly and injector clamp.
2. Center the compression plate over the injector and install the
3/8"-16 all-thread rod in the cylinder head through the holes for
the clamp.
3. Turn the 3/8" nuts down evenly on both sides while holding the
plunger in the up position as the spring is being compressed. Hold
the plunger in the up position with a suitable tool placed through
the spring coils and under the cross-bolt of the unit injector.
4. Remove the keepers and carefully loosen the compression plate. The
plunger should only move as far as the cross-bolt allows.
5. Install the new spring using a suitable tool placed through the
coils of the spring to raise the plunger to its highest position.
Compress the spring and install the spring retainer. Be sure that
the spring is installed with the dampening coil down. The blue
painted coils are at the opposite end of the spring from the
dampening coil.
6. Use the procedures and specifications in the Service Manual and do
the following:
a) Install the injector clamps. b) Install the rocker arms.
7. Repeat this procedure for the remaining cylinders.
8. Use the procedures and specifications in the Service Manual to set
the bridge and valve clearances as well as the injector timing.
****** IMAGE: SEBE4022.00001.001
CAPTION:
Fabricated Tool List
The following tools can be use to install a new spring in a unit
injector without removing the injector from the cylinder head.
Quantity Description
1 Fabricated Compression Plate
(See the illustration)
2 5/16"-18 All Thread Rods 5.2" Long
2 5/16"-18 Nuts
2 5/16" Washers
2 3/8"-16 All Thread Rods 8.0" Long
2 3/8"-16 Nuts
2 3/8" Washers
****** IMAGE: SEBE4022.00001.002
CAPTION: