PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED INJECTORS ON CERTAIN 988F AND 990 WHEEL LOADERS; D9R TRACK-TYPE TRACTORS; 769D, 771D, 773D, AND 775D TRUCKS; 631E, 633E, 637E, 651E AND 657E WHEEL TRACTOR SCRAPERS; 834B WHEEL DOZER; 836 WHEEL TRACTOR SCRA
Usage:
SEBE6860-08
April 24, 1999
(Revised April 2001)
U-108
A-90
AU-73
S-69
H-47
O-101
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| After failure only |
PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED INJECTORS ON CERTAIN 988F AND 990 WHEEL LOADERS; D9R TRACK-TYPE TRACTORS; 769D, 771D, 773D, AND 775D TRUCKS; 631E, 633E, 637E, 651E AND 657E WHEEL TRACTOR SCRAPERS; 834B WHEEL DOZER; 836 WHEEL TRACTOR SCRAPERS; 69D AND 73D UNDERGROUND TRUCKS; 3408E AND 3412E INDUSTRIAL ENGINES; 24H MOTOR GRADERS; PM565 AND PM565B ASPHALT PAVERS |
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| 1290 |
PS5615
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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 not be be administered unless the customer is using a 2 micron secondary fuel filter and using either the preferred CG-4 or CF-4 Oil.
NOTE: This Revised Service Letter replaces the April 24, 1999 (Revised March 2001) Service Letter. Changes have been made to Parts Needed and to add the note above.
TERMINATION DATE
April 30, 2002PROBLEM
On certain machines, the 1388754, 1388755, or 1388756 Injectors may experience a failure. This can be caused either by:- Or
AFFECTED PRODUCT
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| Model | Identification Number |
| 631E |
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| 637E |
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| 631E |
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| 633E |
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| 988F |
200-301, 303-343, 345-493, 495-588, 590-594, 596-886, 888-951, 953-974, 976-1006, 1009- 1035, 1037-1054, 1056-1153, 1155-1278, 1280- 1316, 1318-1347 |
| 990 |
303-312, 314-336, 338-348 |
| 651E |
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| 769D |
5TR69-120, 122-130, 132-158, 160-431, 433-455, 457-493, 495-601, 603-657, 659-663, 665-801, 803-846 |
| 657E |
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| 771D |
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| 775D |
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| 657E |
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| 834B |
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| 773D |
7ER73-155, 157-168, 170-345, 347-382, 384-432, 434-522, 524-571, 573-723, 725-796, 798-849 |
| 836 |
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| D9R |
626, 629-630, 632, 635, 638-675, 677-685, 687- 709, 711, 713-716, 719-726, 728-750, 752-763, 765-768, 770-858, 860-875, 877-938, 940-1017, 1021 8BL830, 832, 834, 849, 851-853, 867, 878-885, 894-895, 897-899, 905-906, 909, 911-914, 917- 918, 920, 922-924, 927-928, 930-933, 937, 939, 947, 951-957, 959-961, 970-971, 973-974, 984- 985, 989-992, 995-1001, 1004, 1006-1017, 1019- 1021, 1023, 1029-1033, 1038-1040, 1043-1044, 1053, 1056, 1058-1062, 1064-1065, 1067-1068, 1074, 1079-1085, 1088, 1093-1094, 1101-1103, 1106, 1109, 1119, 1122, 1125-1126, 1132, 1144, 1146, 1149, 1155-1156, 1158, 1163-1165, 1168- 1169, 1172-1174, 1177-1189, 1198, 1200-1202, 1204, 1206-1214, 1220, 01223-01226, 1229-1241, 1248, 1251, 1254, 1258 |
| 69D |
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| 24H |
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| PM565 |
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| PM565B |
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| 3408E |
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| 3412E |
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PARTS NEEDED
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| Parts needed for the PM565B and certain 4CR Industrial Engine arrangements 131-4015, 131-5359, 131-4016, 131-5360 and certain 7PR Industrial Engine arrangements 130-9477, 127-4668, 131-9262, 132-1981, 132-1982, 132-1983. | ||||
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ACTION REQUIRED
- Use the cylinder cut out test to determine if an individual
Cylinder Cutout Test
- Warm engine out of Cold Mode.
- Increase engine RPM to about 1000.
- Using service tool ET, prepare to perform a cylinder cutout test while the engine is running.
- Cut out one whole bank of cylinders noting engine rpm and the fuel position on the ET screen at that time.
- Cut out one of the remaining cylinders from the running bank, allow engine to stabilize, and note the fuel position.
- Power that cylinder back up and note the fuel position, allow engine to stabilize.
- Repeat steps 5 through 6 until the bank has been completely checked.
- Power all cylinders and allow engine to stabilize.
- Cut out the other bank of cylinders and repeat steps 5 through 8.
- Compare fuel position readings.
- If fuel position did not change (increased) when the cylinder was cut out, then that cylinder may not have been producing power prior to cutout and is suspect.
- When finished with the test, decrease engine RPM to low idle or shut engine off.
and to the same engine serial number is required
within 120 calendar days, replace all of the
remaining injectors that are not part number 1747526, 1747528, 1590838, 1747527, 1590835, and 1590836 to avoid a fourth visit.
Poppet Valve Leakage Test
- Warm engine out of Cold Mode to normal operating temperature.
- Shut down the engine.
- Remove the valve cover bolts in preparation to observe the injectors. Leave covers in place.
- Restart the engine and run at low idle, no load.
- Using the ET service tool, perform injection actuation override test and increase injection actuation pressure to max value.
- Observe all injectors under each valve cover for leakage at the spill port. A small amount of dripping is acceptable, but a continuous stream of oil is an indication of excessive poppet valve leakage. Only leaks at the spill port are an indication of excessive poppet valve leakage.
- If an injector is discovered with excessive poppet valve leakage, all of the remaining injectors that are not part number 1745428, 1590838, 1747526, 1747527, 1590835, 1590836 need to be replaced.
CAUTION: Precautions should be taken to prevent contact with
HOT ENGINE OIL
poppet valve leakage must be properly marked to
show which injector(s) has the excessive leakage.
Then return the complete set to the Peoria Claims
Room.
NOTE: Special tooling is required, carbon clean
out of
the injector sleeves, and proper injector
installation torque sequence are extremely
important to achieve proper installation.
Failure
to follow the Special Instructions "Check
List" may
cause severe damage to the injectors or engine
and
may result in claims being denied. Proof of
use of
the proper tools and procedures will be required.
NOTE: Do not reuse the grommets on top of the injector.
SERVICE CLAIM ALLOWANCES
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If all injectors are replaced:
All 3408E Powered Machines
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PARTS DISPOSITION
Return Individual Injector(s) to:
Attn: PS5615
4-H Park Road
Pontiac, IL 61764
Attn: PS5615
Service Claims Room
8201 N. University
Peoria, IL 61615
warranty parts handling.
Caterpillar Information System:
Circuit Breakers Need To Be Inspected On Certain 3208, 3304, 3304B, G3306, 3306, 3306B, 3406, 3406C, 3408B, 3408C, 3412, Generator Sets Circuit Breakers Need To Be Inspected On Certain 3208, 3304, 3304B, G3306, 3306, 3306B, 3406, 3406C, 3408B, 3408C, 3412, Generator Sets
Product Support Program For Replacing EIS Software Chips On Certain G3508, G3512, And G3516 Engines Product Support Program For Replacing EIS Software Chips On Certain G3508, G3512, And G3516 Engines
The Air Inlet Pipes Need To Be Inspected And Possibly Cleaned On Certain 3512B, 3516, And 3516B Generator Set Engines The Air Inlet Pipes Need To Be Inspected And Possibly Cleaned On Certain 3512B, 3516, And 3516B Generator Set Engines
Service Letter Cancellation Service Letter Cancellation
Product Support Program For Converting Four Cylinder Air Compressor Air Supply From Boosted To Naturally Aspirated On Certain 3176B, C-10, C12, And 3406E Engines Product Support Program For Converting Four Cylinder Air Compressor Air Supply From Boosted To Naturally Aspirated On Certain 3176B, C-10, C12, And 3406E Engines
The Radiator Fan Support Beam Needs To Be Replaced On Certain 3508, 3508B, 3512, 3512B, 3516, And 3516B Generator Sets The Radiator Fan Support Beam Needs To Be Replaced On Certain 3508, 3508B, 3512, 3512B, 3516, And 3516B Generator Sets
0R0824, 0R2089, 0R2128, 0R2170, 0R2586, And 0R2666 Remanufactured Cylinder Heads For D343 Engines May Need To Be Removed From Dealer Parts Stock 0R0824, 0R2089, 0R2128, 0R2170, 0R2586, And 0R2666 Remanufactured Cylinder Heads For D343 Engines May Need To Be Removed From Dealer Parts Stock
Product Support Program For Flashing New Software On C-10 Engines Product Support Program For Flashing New Software On C-10 Engines
Certain Remanufactured Cylinder Packs, Short Blocks, Long Blocks, And Engines Need To Be Removed From Dealer Parts Stock Certain Remanufactured Cylinder Packs, Short Blocks, Long Blocks, And Engines Need To Be Removed From Dealer Parts Stock
Service Letter Cancellation Service Letter Cancellation
100-2825, 137-4729, 0R8575, 0R3650, And 6I2917 Injector Groups Need To Be Inspected 100-2825, 137-4729, 0R8575, 0R3650, And 6I2917 Injector Groups Need To Be Inspected
Engine Emission Labels And An Owner Notification Letter Will Be Provided To Owners Of Certain 3304B Generator Sets Engine Emission Labels And An Owner Notification Letter Will Be Provided To Owners Of Certain 3304B Generator Sets
A Prelube Pump Group And The Continuous Prelube Lines Group Need To Be Installed On Certain G3516 Generator Set Engines A Prelube Pump Group And The Continuous Prelube Lines Group Need To Be Installed On Certain G3516 Generator Set Engines
Product Support Program For Repairing Cracked Exhaust Manifolds On Certain 3516 Marine Engines Product Support Program For Repairing Cracked Exhaust Manifolds On Certain 3516 Marine Engines
Product Support Program For Updating The Metal Particle Detector Lines Group On Certain 3606, 3608, And 3612 Engines Product Support Program For Updating The Metal Particle Detector Lines Group On Certain 3606, 3608, And 3612 Engines
The Starter Solenoid Needs To Be Replaced On Certain 3176B, 3176C, 3196 And 3406E Marine Engines The Starter Solenoid Needs To Be Replaced On Certain 3176B, 3176C, 3196 And 3406E Marine Engines
The Damper Bolts Need To Be Tightened To The Proper Torque On Certain G3408 And G3412 Engines The Damper Bolts Need To Be Tightened To The Proper Torque On Certain G3408 And G3412 Engines
Product Support Program For Rebuilding Remanufactured 0R4105, 0R8310, 0R4106, 0R8311, 0R8306, 0R8312, 0R8308, 0R8313, And 0R8309 Self-Contained Woodward Governors Used On Certain D11N Tractors; 776B, 776C, 776D, And 784B Tractors; 777B, 777C, 777D, 7 Product Support Program For Rebuilding Remanufactured 0R4105, 0R8310, 0R4106, 0R8311, 0R8306, 0R8312, 0R8308, 0R8313, And 0R8309 Self-Contained Woodward Governors Used On Certain D11N Tractors; 776B, 776C, 776D, And 784B Tractors; 777B, 777C, 777D, 7
The Terminal Blocks On The Emcp II Control Panel Need To Be Replaced On Certain 3508, 3508B, 3512, 3512B, 3516, And 3516B Generator Sets The Terminal Blocks On The Emcp II Control Panel Need To Be Replaced On Certain 3508, 3508B, 3512, 3512B, 3516, And 3516B Generator Sets
Product Support Program For Correcting False Overcrank Fault\shutdown During Starting On Certain G3508, G3512, And G3516 Industrial And Generator Set Engines Product Support Program For Correcting False Overcrank Fault\shutdown During Starting On Certain G3508, G3512, And G3516 Industrial And Generator Set Engines
The Battery Cables Need To Be Rerouted On Certain 3406C Generator Set Engines The Battery Cables Need To Be Rerouted On Certain 3406C Generator Set Engines
The Rivet That Holds The Governor Link To The Rack Bar Needs To Be Inspected On Certain 3116 Mechanically Unit Injected (MUI) Truck Engines The Rivet That Holds The Governor Link To The Rack Bar Needs To Be Inspected On Certain 3116 Mechanically Unit Injected (MUI) Truck Engines
New Software Needs To Be Flashed On Certain 1999 My C-10, C-12, And 3406E Truck Engines Used With The 10 And 18 Speed Eaton Autoshift Transmission New Software Needs To Be Flashed On Certain 1999 My C-10, C-12, And 3406E Truck Engines Used With The 10 And 18 Speed Eaton Autoshift Transmission
Upgrade Software Needs To Be Installed On Certain 3606, 3608, 3612, And 3616 Diesel Engines With The Marine Monitoring System (mms) To Become Y2K Compatible Upgrade Software Needs To Be Installed On Certain 3606, 3608, 3612, And 3616 Diesel Engines With The Marine Monitoring System (mms) To Become Y2K Compatible