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 only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5384" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
NOTE: This Revised Service Letter replaces the December 11, 1997 Service Letter. Changes have been made to the Parts Needed.
Termination Date
December 31, 1998Problem
Certain 3116 and 3126 HEUI Truck Engines may have a high pitched squeal or chirp while operating under heavy load and high oil temperature.
Affected Product
Model & Identification Number
Group 1
3116 (8WL1-Up)
Group 2
3126 (1WM1-Up 4ES1-Up )
Parts Needed
Group 1
- 1 - 1R0739 Filter
- 6 - 0335853 O-Ring
- 6 - 1136303 O-Ring
- 6 - 1480876 Tuned Fitting
- 6 - 1492716 Orificed Jumper Tube
- 6 - 0335853 O-Ring
Group 2
- 1 - 1R0739 Filter
- 6 - 0335853 O-Ring
- 6 - 1136303 O-Ring
- 6 - 1480876 Tuned Fitting
- 6 - 1488047 Orificed Jumper Tube
- 6 - 0335853 O-Ring
Action Required
See the attached rework procedure.
Service Claim Allowances
NOTE: An additional 1.6 hours may be claimed using SMCS Code 1714-500 if required when the rework is performed in a Motor Home, cab type (RV) or Bus (BU).
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
1. Check to see if the dipstick has been re-calibrated using a scribe pencil.
2. Re-calibrate the oil level gauge (dipstick) before installing new jumper tubes. See the attached pages entitled "3100 HEUI Oil Level Correction". Check the engine to see if this corrects the squeal.
3. Remove jumper tubes and tuned fittings from intake manifold. Use a new 1480876 Tuned Fitting and 1492716 Jumper Tube for Group 1 and a 1480876 Tuned Fitted and 1488047 Jumper Tube for Group 2.
4. Install the 1480876 Tuned Fitting into the manifold and tighten to a torque of 25 ± 3 N·m (18 ± 2 lb ft).
5. Install the 1492716 or the 1488047 Tube Assembly into the manifold end first, then the injector end. Start the flare nut into the manifold and tighten by hand until flare nut is seated on the tuned fitting.
6. Install the (2) 1253296 Bolts (#10 socket head) at the injector end of the tube. Tighten evenly until hand tight.
7. Tighten the flare nut at the manifold to a torque of 40 ± 5 N·m (30 ± 4 lb ft). Loosen until tube is center in flange and retighten to 40 ± 5 N·m (30 ± 4 lb ft).
8. Tighten each 1253296 Bolt (#10 socket head) to 3 N·m (27 lb in) then tighten each 1253296 Bolt (#10 socket head) to 5 N·m (45 lb in).
9. Install the 1265424 or 1355973 Clamp with a 9M1974 Washer, 1077808 Washer and 8T0292 Bolt. Tighten the bolt to 30 ± 4 N·m (22 ± 3 lb ft).
10. Tighten the flare nut to a torque of 40 ± 5 N·m (30 ± 4 lb ft).
11. Tighten the clamp bolt to 30 ± 4 N·m (22 ± 3 lb ft).
12. Tighten the 1253296 Bolt (#10 socket head) to a torque of 5 ±1 N·m (45 ± 9 lb in).
Illustration 1
3100 HEUI Oil Level Correction
The refill quantities specified in the 3100 HEUI Operation and Maintenance Manual, SEBU6885, prior to the July 1997 issue are in error. These manuals stated that refill capacity for the stamped steel shallow pan, P/N 1154170, was 21 L (22 qt.), and for the early cast aluminum deep pan, P/N 1193030, was 31 L (33 qt.). That did not take into account the amount of oil contained in the HEUI hydraulic system. We have reduced the refill quantities to allow for the approximately 3.5 quarts retained in the hydraulic system. It will be necessary to drain and refill to the quantities given in the table below, after which the dipstick must be recalibrated. The procedure is given below. This document applies to all 3100 HEUI engines.
System capacity for the shallow pan, P/N 1154170, is 21 L(22 qt.), and system capacity for the early aluminum deep pan, P/N 1193030, is 31 L (33 qt.). Another deep pan with 32 L (34 qt.) system capacity, P/N 1265930, was used beginning about mid-1995 and is used in current production. A new deep pan, P/N 1443483, will also have a system capacity of 32 L (34 qt), and will cancel and replace the former one in production and parts service sometime in December 1997.
A higher than normal oil level in the engine may result in one or more of the following problem:
The HEUI squeal has been eliminated in some cases by reducing the oil level, and this is recommended prior to installing the orificed jumper tubes (they may not be needed in all cases).
Normal blowby in a new 3116 or 3126 engine has been established at 1.2 x hp = blowby in cubic feet per hour, measured on a dynamometer at rated load and speed (TENews, March 1996). Example: 200 hp x 1.2 = 240 cu. ft. / hr. Anything higher than twice this figure is cause to investigate. It is important to distinguish between the volume of blowby and the amount of oil mist contained in the breather fumes. An engine may be well within specification on volume, but have excessive oil mist.
3116 HEUI and 3126 HEUI Engine Lubrication System Capacity (Approximate)
NOTE: (1) Approximate crankcase system capacity including standard factory installed filters.
Engines with auxiliary oil filters will require additional oil.
- LUBERFINER (R) 500 C - Add 9.5 L (10 qt.)
- LUBERFINER (R) 750 C - Add 13.25 L (14 qt.)
Illustration 2
To determine oil change interval, refer to the graph in the Maintenance Section of the 3100 HEUI Operation and Maintenance Manual, SEBU6885.
Change Engine Oil and Oil Filter
After the engine has been operating at normal operating temperature, stop the engine. Remove the crankcase oil drain plug and allow the oil to drain for 20 minutes. Clean the oil drain plug and install it. Tighten the oil drain plug to 25 ± 5 N·m (I 8 ± 4 lb ft). (Ref. 3100 HEUI OMM.)
Remove the oil filter with a I U8769 chain wrench. Clean the sealing surface of the oil filter mounting base and be sure all of the old gasket is removed. Apply clean engine oil to the new oil filter gasket. Install the new oil filter until the gasket contacts the oil filter mounting base. Tighten the oil filter of a turn (270 degrees) more by hand. Do not over tighten.
Illustration 3
Check Oil Level Gauge (Dipstick) Calibration at First Oil Change
Engine oil level will vary depending on angle and slant of the engine installation (angle = front to back tilt, slant = sideways tilt).
The vehicle must be parked on a level surface to perform this maintenance procedure.
It is a good idea to verify that the oil level gauge markings are correct. The most convenient time to verify the markings is when the oil is changed, preferably at the first oil change. To verify the ADD mark and to establish the actual FULL mark on the oil level gauge, use the following procedure:
Refer to the 3116 HEUI and 3126 HEUI Engine Lubrication System Capacity Table above to determine the quantity of oil required. Pour the Add Mark volume of oil into the crankcase.
To prevent crankshaft or bearing damage, crank the engine with the fuel OFF in order to fill all of the oil filters before starting. Do not crank the engine for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking again.
DO NOT load or accelerate the engine before achieving oil pressure on the gauge.
Start the engine and operate it long enough to ensure that the lubrication system (including auxiliary filters, etc.) has oil and that the oil filter(s) are filled. Inspect for oil leaks.
Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes. Check the oil level. This will be the new ADD mark. If it does not match the existing ADD mark, grind off the existing ADD mark and engrave a new ADD mark, using an engraving pen.
Add three liters (three quarts) of oil to the engine. Allow enough time for the oil to drain into the pan. Check the oil level on the gauge. This will be the new FULL mark. If it does not match the existing FULL mark, grind off the existing FULL mark and engrave a new FULL mark, using an engraving pen.
If a fleet of trucks is involved, and many or all of them have the same engine and same engine arrangement, then do the first one in each group having the same arrangement as described above. Then use the oil level gauge from this truck as a guide to re-mark all the oil level gauges from trucks having the same engine and same arrangement. Use the re-marked gauges to determine correct oil level in the remaining trucks. Remove oil as necessary to match the new FULL mark. This does not require changing the engine oil or oil filter.
Record the new REFILL oil capacity in the truck's logbook for future reference.