Product Support Program For Installing Series Fuel Filters On Certain 924F Wheel Loaders And IT24F Integrated Tool Carriers Caterpillar


Product Support Program For Installing Series Fuel Filters On Certain 924F Wheel Loaders And IT24F Integrated Tool Carriers

Usage:

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Caterpillar: Confidential Yellow

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 "PS4583" 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.

Termination Date

October 31, 1999

Problem

Certain IT24F Toolcarriers and 924F Wheel Loaders may experience hard starting when the engine is warm or hot. This problem may be due to internal wear of the scroll-edges on the fuel injector plungers. The wear is caused when very fine dirt in the fuel gets past the filter, or by the practice of pre-filling the fuel filter with dirty fuel when the filter is changed.

Affected Product
Model & Identification Number

IT24F (4NN1-1289

924F (5NN1-1451, 4YN1-1670 )

Parts Needed

1 - 1J9671 SEAL-O-RING
3 - 3J1907 SEAL-O-RING
1 - 7K1181 STRAP-CABLE
2 - 8M2773 CLIP
1 - 6N4414 COVER-F FIL
1 - 1P0436 GASKET-PR PU
2 - 5P4961 CLAMP-HOSE
1 - 6R5044 HOSE AS
3 - 8T4121 WASHER-PLATE
2 - 8T4136 BOLT
1 - 8T4137 BOLT
3 - 8T4224 WASHER-PLATE
1 - 8T4908 BOLT
1 - 8T5043 CONNECTOR
2 - 8T7547 BOLT
1 - 8T8902 TEE-SWIVEL
6 - 6V8397 SEAL-O-RING
1 - 7X2533 BOLT
1 - 7X2537 BOLT
1 - 7X2552 BOLT
1 - 8X6603 HOSE AS
1 - 9X8256 WASHER
1 - 9X8257 WASHER
2 - 1R0751 FILTER AS
80 - 1032529 HOSE (BULK cm)
1 - 1200201 BASE AS-F FL
1 - 1266872 TEE-ORFS TO
1 - 1353327 PLATE AS
1 - 1416378 BRACKET AS
2 - 1418275 VALVE-DRAIN

Action Required

1. Install the new Series Fuel Filter parts. The new filter being added provides additional filtering and is installed "upside-down" to prevent customers from pre-filling with contaminated fuel.

2. If needed, replace worn injectors on machines in service.

There have NOT been any changes to the injectors themselves related to the hot hard starting problem. Injector replacement is not needed unless the machine is experiencing hot hard starting due to worn injectors.

NOTE: After-failure coverage for replacement of worn injectors is intended only for those Customers who use genuine Caterpillar Fuel Filters. Injector replacement expense should be for the customers account if engine is equipped with a non-Cat Fuel Filter.

3. Instruct the customer, operator and/or maintenance personnel concerning the installation of the new series fuel filter group, change intervals, and the need to drain Filter 2 anytime either filter is changed. Provide the customer with a copy of the "SERIES FUEL FILTER CHANGE AND MAINTENANCE INTERVAL INSTRUCTION INFORMATION" that is attached to this Service Letter. Instruct the customer to add the copied sheets to the Operations and Maintenance Guide for their machine.

Service Claim Allowances

NOTE: This is a 2.6-hour job.

NOTE: 3.2 additional repair labor hours are required if injector replacement is needed. Use the labor percentage above, based on machine hours or age for participation purposes.

Parts Disposition

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Attach.

(1-Rework Procedure)
(1-Series Fuel Filter Change and Maintenance Interval Instruction Information)
(1-Procedure to verify that Injectors are worn)

Rework Procedure

INSTALLATION OF "SERIES" FUEL FILTERS

An additional secondary fuel filter (filter No. 2) is being added to 3114 engines in the IT24F Toolcarriers or 924F Wheel Loaders. The additional "Filter No. 2" is in "series" after the first fuel filter, and provides dual-filtering of the fuel for extra cleanliness. Filter No. 2 also acts as a final "Safety element" similar to the inner element of an air cleaner. Both fuel filters will be "High Efficiency" filters rated at 2-microns.

Filter No. 2 is installed "upside-down" to prevent the practice of pre-filling filters with fuel that could be contaminated.

NOTE: If injectors are worn, and need to be replaced, we recommend installing a new 1R0751 Fuel Filter and operating the machine at High Idle for at least 30 minutes to "flush out" any dirt that may be in the clean-side of the fuel system and cylinder head, before changing injectors. Refer to the "Procedure To Determine If Injectors Are Worn" and "Injector Replacement" for additional information.

Installation on Machine: The engine in the IT24F and 924F machines are installed with the front (fan side of engine) pointing to the rear of the vehicle. For the purpose of the conversion, all instructions are written in reference to the rear of the machine which is the front of the engine.

1. Open the right access door on the machine to gain access to the engine fuel filter and fuel system.

2. Drop bottom access panel to gain better access to the side of the engine.

3. Remove the original steel fuel line which connects the No. 1 fuel filter outlet to the rear of the cylinder head and discard that fuel line. See Illustration 2.

4. Loosen the Tee at the No. 1 fuel filter outlet and rotate it so that the connection for the tee points "Down" and Retighten.

5. Prior to installing the parts for filter No. 2, locate the mounting bolts in the cylinder block that will be used to install the 141-6378 Fuel Filter Base Mounting Bracket As. Remove the M8 bolt that clips the wiring harness to the cylinder block and Discard the bolt. Do not Discard the Clip and washer as it will be required when the bracket as. is installed. Insure the threads in those tapped holes are clean. (It may be necessary to use an M10 thread tap to clean the threaded holes.) See Illustration 3

6. Use the parts list at the beginning of this letter plus Illustration 3 for guidance in installing the necessary parts for the conversion.

7. When installing the 2-1R0751 fuel filters on filter base No. 1 and new base No. 2, be sure to tighten the filters one full turn after the filter seal contacts the base.

8. After installation, use the hand priming pump to fill the filters and fuel system. To improve fill, open the fuel outlet drain valve (B). Place a container under the drain valve hoses to catch fuel and use the hand priming pump to prime the new filters and fuel system. Stop priming, and CLOSE drain valve (B) when fuel begins to flow out of the drain hose. After closing valve (B) stroke the priming pump an additional 5 strokes to insure that priming is complete. Be sure to check for leaks while priming.

9. Start the engine, and check all lines, fittings and connections for fuel leaks. Be sure BOTH drain valves for the upside down Fuel Filter No. 2 are CLOSED.

Series Fuel Filter Change Interval And Maintenance Instruction Information

NOTE: Use ONLY genuine Caterpillar Fine Micron Filters (2-micron). Use of other filters may result in inadequate filtering and fuel system damage.

The recommended replacement interval for the new Series Filters Conversion is:

Filter Number 1 500 Hours # 1R0751 (original filter location)

Filter Number 2 500 Hours # 1R0751 (new "upside-down" filter)

# - More often if needed, such as low power or other symptoms due to clogged fuel filters.

The recommended series filter replacement instructions are as follows:

NOTE: Because this machine is now equipped with series filter it is important to remember that the "upside down" inverted filter must always be drained prior to the removal and replacement of the fuel filters.

1. Shut off the fuel tank supply valve.

2. See Illustration 1. Drain the upside down (inverted) filter. To drain, place a suitable container under the drain hoses connected to drain valves (A) and (B). Refer to Illustration 1. Open the rear drain valve (B) first and then immediately open drain valve (A). It is important to open these valves as noted as opening the wrong valve first may cause a fuel system air lock and not allow fuel to drain from the upside down filter. Allow fuel to drain. When drainage stops, leave valve (A) and (B) open and slightly loosen the upside down filter (loosen approximately one-quarter turn). As the filter is loosened additional fuel may drain from valves (A) and (B). When fuel drainage stops, loosen the filter an additional one-quarter turn and observe flow. Repeat this procedure until fuel no longer drains from the valves. Close valves (A) and (B) and properly dispose the drained fuel.

3. Remove Fuel Filter No 1 and 2. Note: Filter No 1 has not been drained and has fuel in it. Caution should be taken when removing this filter to avoid fuel spillage.

4. Clean the fuel filter mounting bases. Make sure that the seal from the filters are not stuck to and on the bases.

5. Coat the seals of the new filters with clean diesel fuel.

6. Install the new filters. Hand tighten the filters until the filter seals contact the sealing surfaces on the bases then tighten the filters one additional full turn.

Rotation index marks are positioned on the filters at 90 degree intervals. Use these marks as a guide when you tighten the filters.

7. Open the Fuel Tank Supply Valve which was shut off in step number 1.

8. Prime the fuel system. When priming the fuel system open drain valve (B) to allow air trapped in the filters to escape. Operate the priming pump plunger until fuel begins to flow out the drain valve (B). When fuel begins to flow out of valve (B) close the valve. Operate the priming pump an additional 5 strokes to insure that the remaining fuel system is primed and all of the air is purged from the fuel lines.

9. Start the engine and check for fuel leaks. Make sure that drain valve (A) and (B) are completely closed before starting.


Illustration No 1 - Filter and drain valve locations.

Procedure To Determine If Injectors Are Worn

If a Customer is complaining of hard starting at the time that the machine is brought in for the series filter up-date, or the machine demonstrates hard starting prior to the installation of the series filter conversion, it will be necessary to determine if the problem is worn injectors. Following is information that will help you identify if a machine is eligible for injector replacement. "Hard Starting" symptoms can have several causes. However, it is relatively easy to determine certain causes, and eliminate others by evaluating the specific circumstances when "hard starting" occurs. The following is a list of the most common causes of "hard starting", followed by a discussion of each.

- Worn Injectors ("hot" hard starting)
- Control Shaft Sticking
- Fuel Siphoning (Air In Fuel)
- Cold Weather

NOTE: This Program covers ONLY hot hard starting due to worn injectors.

WORN INJECTORS:

Symptom:Machine is hard to re-start after it reachesnormal "hot" engine operating temperature and is shut-down.Usually, the machine will start easily when the engine is cool, such as the first start of the day. Difficulty re-starting when "hot" (if due to worn injectors) may be due to the loss of injectorplunger/barrel pumping efficiency because hot fuel is thinner than cold fuel and plunger/barrel leakage is to high at cranking rpm (200 to 250 rpm).

TEST:

a) Run the engine until it reaches normal operating temperature and shut it down.

b) Remove the engine valve cover and install the Indicator Fixture Gp. and Indicator as if you were going to check the engine fuel setting (rack setting). See topic "Fuel Setting" in the Systems Operation Test and Adjusting Section of the Engine Service Manual for details on tooling.

NOTE: When installing the fixture gp and indicator it will not be necessary to remove the fuel shut-off solenoid.

c) Zero the Indicator with the fuel shut-off solenoid in the Fuel Shut-off Position.

NOTE: The IT24 and 924 utilize an energize to run (ETR) latching type fuel shut-off solenoid which energizes when the key switch is turned to start and the starter engages.

d) After zeroing the indicator turn the key switch to the start position and crank momentarily to energize the latching type solenoid. Observe for movement of the indicator. The indicator should move from the 0.0mm position to a positive position (.5 to 2.0mm). If no movement is observed, see topic "Control Shaft Sticking".

e) Continue to observe the indicator and turn the key to the off position and then back to the "start" (crank) position. As the engine turns over the rack should start moving from the .5 - 2.0mm position to a higher positive position. As the rack increases observe the point at which the engine fires (starts). It should start when the rack reaches 2.0 to 4.0mm. If the rack increases to more than 4.0mm and the engine fails to start, the injectors are worn and require replacement (See Topic "Injector Replacement" for additional instructions). If the rack fails to move or hesitates to increase as the engine is cranked, see the topic "Control Shaft Sticking".

CONTROL SHAFT STICKING: Sometimes "hard starting" can be corrected by exercising the throttle (governor control) while cranking.If the throttle is moved to the full fuel on position, back to idle and then to or throttle position, and the engine starts then the cause of hard starting is not worn injectors. If exercising the throttle allows an engine to start, it means that at the "low idle" position, the governor does not have enough force to open the rack control shaft. Usually, the cause of this problem is an improperly adjusted Fuel Control Shaft Assembly. Exercising the throttle as noted, during cranking, changes the control linkage position and causes the governor to exert more force on the control shaft mechanism thus forcing the injector racks to move and allows the engine to start. This is usually traced to improper control rack as. installation and adjustment. Specifically, adjustment of the two center-supports for the control shaft must be done properly or the shaft may not rotate freely, and may "stick" in the fuel-off position. Refer to Special Instruction Form SEHS9730, Service Magazine Article dated Jan 17, 1996, or the control shaft adjustment procedure given in the "Disassembly and Assembly" part of Engine Service Manual, SENR3611 (04/95) or later, for the control shaft adjustment procedure.

Improper fuel control shaft adjustment usually results in symptoms immediately after installation, such as a new engine, or immediately after repairs involving installation of injectors or the control shaft as. Improper adjustment usually shows up as hard starting when the engine is cold but can also show up when the engine is warm.

FUEL SIPHONING (Air In Fuel): If hard starting can be resolved by "priming" the engine with the hand priming pump, then "worn injectors" are not likely the cause.

If an engine starts when primed, the cause is likely to be "fuel siphoning" or "bleed-down". This occurs when fuel leaks from the cylinder head back to the tank and is replaced by air. Air causes a lack of fuel for combustion and results in hard starting. Use "Priming the engine" as an easy diagnostic method to determine if "fuel siphoning" or "bleed-down" is a problem. This symptom usually occurs when the machine has shut off for some period of time such as overnight or over a weekend allowing time for "siphoning" to occur. Therefore, "hard starting" usually occurs at the first start-up of the day. With a "fuel siphoning" problem, the machine will usually start normally when the engine is hot or warm, if it is started shortly after it is shut down. There have been occasional reports of siphoning causing hard starting in as little as one hour.

Fuel siphoning is normally traced to a faulty "return-to-tank" check valve, suction side fuel system leak, or in some cases, injector to cylinder head sleeve leakage.

COLD WEATHER: Hard starting only in cold weather is NOT due to worn injectors.

If an engine is hard to start when temperatures are below 0 degrees C (32 degree F) the hard starting problem is simply related to cold climate temperatures. There are some cold-weather considerations provided in the "Operation & Maintenance Manual - Cold Weather Recommendations" for Cat Machines. See that information. The following represent some of the items to consider if cold hard starting occurs:

* Use "No. 1" grade diesel fuel, or kerosene mix to improve starting. Check the fuel API rating.
* Cold Cranking RPM - If engine "cranks" too slowly (normal cranking is 200 t0 250 rpms) check the battery, electrical system, battery capacity, cable size, connections etc.
* Use a lighter weight engine oil suitable for the coldclimatic temperatures. Refer to Operation & MaintenanceManual.
* Use "Starting Aids" such as electric coolant heater(block heaters), Ether Starting Aids, etc.
* Many machines with 3116 Engines now offer the Electric Air Inlet Heater System as a starting aid. By pre-heating the electric heater element in the air inlet system, the inlet air is warmed during cranking to improve start-ability. Air Inlet Heater (AIH) systems can be refitted to most machines with 3116 engines, if needed. Refer to the November 6, 1995 and September 27, 1993 Service Magazine articles, "Dealer Installed Air Inlet Heater Starting Aid Available" for information.

INJECTOR REPLACEMENT

FLUSH PROCEDURE (Before installing new injectors)

If injectors are to be replaced due to hot hard starting, it is possible there may be dirt in the "clean" or "filtered" side of the fuel system. Therefore, before replacing worn injectors it is recommended to "flush" the system to make sure the filtered side of the system is as clean as possible BEFORE installing the new injectors. This may be done either before or after installing the new Series filter update.

NOTE: If Series filter update has already been done, then proceed to Step 2.

1. Remove the existing used fuel filter, and install a NEW 1R0751 Fuel Filter in the No. 1 fuel filter location. DO NOT FILL THE NEW FILTER WITH FUEL. Use the hand priming pump to prime the filter.

2. Start the machine, and run the engine at High Idle for at least 30 minutes, or longer. This will allow any dirt in the clean side to "flush" back to tank. The new filter will provide clean fuel during the flushing time.

REPLACEMENT PROCEDURE

1. During injector replacement, do not open the box of each new injector until it is time to install it. Leaving the new injectors open exposes them to fine dust which then is installed with the injector.

2. During injector replacement, do not remove all the injectors at the same time. Instead, remove only one injector and replace it with a new one, before proceeding to the next injector. This will minimize the amount of dust that gets into the injector hole while the injector is removed.

3. When replacing injectors, be sure to ream the brass sleeve before installing the new injector. If brass sleeve replacement is needed, replace each sleeve separately including reaming, and install a new injector before going to the next injector. Also, be sure to remove all the small particles from the reaming process. Use a small amount of spray solvent to wash the injector hole and sleeve before installing the injector.

4. Do not open the box of the new injector until ready to put it in the cylinder head. Servicemen should clean their hands on a clean shop towel as much as possible to avoid getting dirt on the new injectors when handling them. Do not "wipe" the oil off the injector before installing it. Some of the very fine dirt on a wiping towel or cloth will be left on the injector.


Illustration No 2 - Fuel Line that is to be removed.


Illustration No 3 - Parts and locations for Filter No 2.

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