Usage:
NOTE: 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.
NOTE: 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 "PS8305" 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.
NOTE: This Program does NOT apply to engines that were reworked previously as a result of calling the Injector Call Center.
NOTE: This Revised Service Letter replaces the June 2, 1995 Service Letter. Changes have been made to the Affected Product.
Termination Date
December 31, 1995Problem
The tip of the fuel injector assembly may fail on certain 3176B Truck Engines.
Affected Product
Model & Identification Number
3176B (9CK629, 9CK632, 9CK634-636, 9CK639, 9CK644-646, 9CK649, 9CK650, 9CK652, 9CK671, 9CK680, 9CK681, 9CK683, 9CK748, 9CK751, 9CK788, 9CK789, 9CK806, 9CK807, 9CK813, 9CK837, 9CK843, 9CK847, 9CK848, 9CK977, 9CK979, 9CK1029, 9CK1049, 9CK1070, 9CK1086, 9CK1095, 9CK1096, 9CK1154, 9CK1168, 9CK1185, 9CK1222, 9CK1249, 9CK1293, 9CK1325, 9CK1336, 9CK1343, 9CK1347, 9CK1350, 9CK1381, 9CK1395, 9CK1403, 9CK1463, 9CK1530, 9CK1531, 9CK1561, 9CK1676, 9CK1707, 9CK1722, 9CK1766, 9CK1776, 9CK1797, 9CK1823, 9CK1860, 9CK1881, 9CK1883, 9CK2016, 9CK2017, 9CK2041, 9CK2060, 9CK2145, 9CK2190, 9CK2240, 9CK2242, 9CK2244, 9CK2251, 9CK2301, 9CK2328, 9CK2336, 9CK2354, 9CK2424, 9CK2460, 9CK2472, 9CK2495, 9CK2504, 9CK2509, 9CK2519, 9CK2587, 9CK2613, 9CK2621, 9CK2623, 9CK2673, 9CK2676, 9CK2692, 9CK2695, 9CK2702, 9CK2815, 9CK2817, 9CK2826, 9CK2852, 9CK2888, 9CK2912, 9CK2933, 9CK2943, 9CK2953, 9CK2974, 9CK2983, 9CK2987, 9CK2989, 9CK2993, 9CK2994, 9CK3005, 9CK3007, 9CK3045, 9CK3050, 9CK3071, 9CK3085, 9CK3086, 9CK3088, 9CK3093, 9CK3101, 9CK3103-3106, 9CK3108, 9CK3110, 9CK3111, 9CK3137, 9CK3141, 9CK3162, 9CK3180, 9CK3189, 9CK3197, 9CK3204, 9CK3257, 9CK3266, 9CK3280, 9CK3284, 9CK3287-3289, 9CK3296, 9CK3303, 9CK3322, 9CK3328, 9CK3329, 9CK3335, 9CK3384, 9CK3402, 9CK3462, 9CK3472, 9CK3477, 9CK3509, 9CK3536, 9CK3537, 9CK3543, 9CK3565, 9CK3575, 9CK3595, 9CK3607, 9CK3638, 9CK3645, 9CK3652, 9CK3676, 9CK3691, 9CK3725, 9CK3727, 9CK3739, 9CK3741, 9CK3752, 9CK3759, 9CK3770, 9CK3792, 9CK3797-3799, 9CK3815, 9CK3816, 9CK3819, 9CK3823, 9CK3846, 9CK3861, 9CK3863, 9CK3864, 9CK3868, 9CK3871, 9CK3873, 9CK3878, 9CK3905, 9CK3907, 9CK3910, 9CK3913, 9CK3955, 9CK3956, 9CK3961, 9CK3962, 9CK3964, 9CK3974, 9CK3975, 9CK3977, 9CK3989, 9CK4053, 9CK4055, 9CK4068, 9CK4075, 9CK4083, 9CK4085, 9CK4087, 9CK4097, 9CK4100, 9CK4102, 9CK4104, 9CK4113, 9CK4117, 9CK4142, 9CK4172, 9CK4189, 9CK4229, 9CK4245, 9CK4291, 9CK4295, 9CK4311, 9CK4313, 9CK4345, 9CK4348, 9CK4384, 9CK4399, 9CK4406, 9CK4410, 9CK4415, 9CK4416, 9CK4441, 9CK4442, 9CK4467, 9CK4476, 9CK4482, 9CK4504, 9CK4528, 9CK4529, 9CK4544, 9CK4546, 9CK4549, 9CK4554, 9CK4565, 9CK4570, 9CK4584, 9CK4590, 9CK4595, 9CK4616, 9CK4641, 9CK4652, 9CK4658, 9CK4659, 9CK4666-4668, 9CK4676, 9CK4706, 9CK4708, 9CK4712, 9CK4715, 9CK4722, 9CK4732, 9CK4741, 9CK4745, 9CK4748, 9CK4771, 9CK4793, 9CK4798, 9CK4802, 9CK4805, 9CK4816, 9CK4820, 9CK4824, 9CK4844, 9CK4845, 9CK4851, 9CK4853, 9CK4870, 9CK4879, 9CK4882, 9CK4887, 9CK4889, 9CK4892, 9CK4898, 9CK4901, 9CK4903-4905, 9CK4912, 9CK4914, 9CK4916, 9CK4935, 9CK4947, 9CK4949, 9CK4951, 9CK4963, 9CK4965, 9CK5003, 9CK5004, 9CK5024, 9CK5036, 9CK5037, 9CK5041, 9CK5044, 9CK5048, 9CK5063, 9CK5067, 9CK5070, 9CK5072, 9CK5085, 9CK5090, 9CK5091, 9CK5106, 9CK5114, 9CK5115, 9CK5117, 9CK5118, 9CK5131, 9CK5136, 9CK5138, 9CK5140, 9CK5148, 9CK5153, 9CK5173, 9CK5176, 9CK5177, 9CK5179, 9CK5230, 9CK5232, 9CK5233, 9CK5235-5238, 9CK5246, 9CK5248, 9CK5249, 9CK5254, 9CK5271, 9CK5306, 9CK5316, 9CK5331, 9CK5334, 9CK5350, 9CK5351, 9CK5353, 9CK5357, 9CK5365, 9CK5366, 9CK5375, 9CK5378, 9CK5388, 9CK5390, 9CK5392, 9CK5394, 9CK5395, 9CK5398, 9CK5405, 9CK5407, 9CK5415, 9CK5422, 9CK5434, 9CK5436, 9CK5446-5448, 9CK5457, 9CK5490-5492, 9CK5494, 9CK5496, 9CK5498-5500, 9CK5516, 9CK5534, 9CK5537, 9CK5539, 9CK5582, 9CK5585, 9CK5593, 9CK5604, 9CK5618, 9CK5623, 9CK5624, 9CK5647, 9CK5670, 9CK5676, 9CK5687, 9CK5695, 9CK5705, 9CK5725, 9CK5738, 9CK5746, 9CK5753, 9CK5757, 9CK5759, 9CK5769, 9CK5770, 9CK5771, 9CK5775, 9CK5779, 9CK5783, 9CK5794, 9CK5796, 9CK5798, 9CK5803, 9CK5804, 9CK5813, 9CK5821, 9CK5822, 9CK5831, 9CK5835, 9CK5843, 9CK5857, 9CK5874, 9CK5902, 9CK5906, 9CK5913, 9CK5915, 9CK5922, 9CK5925, 9CK5927, 9CK5938, 9CK5956, 9CK5959, 9CK5970, 9CK5974, 9CK5988, 9CK5991-5993, 9CK5997, 9CK6006, 9CK6014, 9CK6019, 9CK6035, 9CK6038, 9CK6039, 9CK6048, 9CK6057, 9CK6075, 9CK6077, 9CK6090, 9CK6110, 9CK6111, 9CK6124, 9CK6126, 9CK6135, 9CK6136, 9CK6156, 9CK6159, 9CK6161, 9CK6163, 9CK6172, 9CK6174, 9CK6180, 9CK6194, 9CK6213, 9CK6218, 9CK6219, 9CK6221, 9CK6222, 9CK6224, 9CK6231, 9CK6250, 9CK6253, 9CK6254, 9CK6256, 9CK6259, 9CK6272, 9CK6278, 9CK6280, 9CK6298, 9CK6305, 9CK6319, 9CK6331, 9CK6332, 9CK6364, 9CK6367, 9CK6371, 9CK6380, 9CK6385, 9CK6388, 9CK6391, 9CK6400, 9CK6402, 9CK6404, 9CK6405, 9CK6407, 9CK6413, 9CK6418, 9CK6422, 9CK6425, 9CK6430, 9CK6434, 9CK6445, 9CK6454, 9CK6468, 9CK6473, 9CK6478, 9CK6480, 9CK6518, 9CK6525, 9CK6535, 9CK6559, 9CK6564-6566, 9CK6571, 9CK6574, 9CK6576, 9CK6580, 9CK6586, 9CK6596, 9CK6601, 9CK6610, 9CK6615, 9CK6628, 9CK6635, 9CK6648, 9CK6667, 9CK6678, 9CK6681, 9CK6683, 9CK6685, 9CK6686, 9CK6688, 9CK6690, 9CK6692-6694, 9CK6696, 9CK6698, 9CK6704, 9CK6711, 9CK6713, 9CK6738, 9CK6754, 9CK6759, 9CK6775, 9CK6781, 9CK6806, 9CK6820, 9CK6823, 9CK6825, 9CK6848, 9CK6856, 9CK6859, 9CK6865, 9CK6867, 9CK6876, 9CK6877, 9CK6896, 9CK6903, 9CK6905, 9CK6914, 9CK6923, 9CK6924, 9CK6927, 9CK6957, 9CK6968, 9CK6971, 9CK6977, 9CK6979, 9CK6981, 9CK7008, 9CK7010, 9CK7020, 9CK7022, 9CK7029, 9CK7031, 9CK7061, 9CK7075, 9CK7077, 9CK7078, 9CK7084, 9CK7095, 9CK7099, 9CK7101, 9CK7110, 9CK7114, 9CK7120, 9CK7126, 9CK7127, 9CK7138, 9CK7143, 9CK7145-7147, 9CK7153, 9CK7216, 9CK7262, 9CK7264, 9CK7341, 9CK7390, 9CK7392, 9CK7394, 9CK7396, 9CK7411, 9CK7435, 9CK7437, 9CK7469, 9CK7483, 9CK7538, 9CK7570, 9CK7571, 9CK7573)
Parts Needed
- 6 - 0R4526 Injector Gp. (For 275 HP Engines)
or
- 6 - 0R4527 Injector Gp. (For 300 and 325 HP Engines)
or
- 6 - 0R4528 Injector Gp. (For 342, 350, 365 and 335/365MT HP Engines)
Action Required
See attached rework procedure.
Service Claim Allowances
Filing Claims
Before Failure Repair
File a claim against PS8305 and include all parts and labor required as part of this program.
After Failure Repair
If the failure involved a cracked or split injector nozzle, the failure can be claimed under PS8305. File one claim against PS8305 and include all parts and labor required to make the complete repair. Explain the reason for any additional parts and/or labor in the claim story.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
1. Check for prior completion of this program by:
- A. Checking SIMS for PS8163 or PS8305.
- B. Checking the engine block for the letters "GS" stamped on the block.
- C. Checking for a "PS8163" label on the valve cover.
- B. Checking the engine block for the letters "GS" stamped on the block.
If there is any indication these programs have already been performed, no further action is necessary.If there is any doubt, call Caterpillar at (309) 578-8590.
2. If there is no indication that the program has already been performed, remove the necessary air piping, air cleaners, valve covers, Jake Brakes, and rocker arm assemblies. Remove the lower plug at the rear of the fuel manifold and drain the fuel from the cylinder head and manifold. Reinstall the plug.
3. Remove the fuel injectors from the engine.
4. Immediately clean off excess engine oil and install protective tip caps from the new injectors. Place the fuel injectors in individual clean plastic bags and wrap the injectors with padding. Be sure to provide adequate padding around the injectors to prevent damage to the electrical terminals and nozzle during shipment.
5. Ream the injector sleeves until the sleeve has been cut to provide a full length concentric taper past the 9X7317 tip seal to sleeve interface.
6. Remove any excess fuel which may have drained into the cylinder.
7. Install the o-ring seals on the injector.
8. Lubricate the two larger o-ring seals with engine oil and install the injectors. Apply 6V4876 Molycote to the hold down bolt threads and torque the bolts to 30 N·m (22 lb ft).
9. Adjust the valves and injectors. Install the Jake brakes if so equipped and adjust to 0.5 mm (.020 in). Complete the assembly.
10. Prime the fuel system as follows:
- A. Open air bleed on the siphon block.
- B. Hand prime to remove air (until fuel is visible).
- C. Close air bleed.
- D. Hand prime until valve opens - valve will "click" open.
- E. Tighten priming pump handle.
- B. Hand prime to remove air (until fuel is visible).
11. Stamp the engine block next to the serial number plate with the letters "GS".