Usage:
January 28, 2003
(Revised May 2003)
D-28
After failure only |
PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED HEUI INJECTORS ON CERTAIN 3412E POWERED 773D OFF-HIGHWAY TRUCKS |
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1290 |
PS50599
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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 administered unless the customer is using a 2 micron secondary fuel filter and using either the preferred CH-4, CG-4, or CF-4 Oil.
NOTE: This Revised Service Letter replaces the January 28, 2003 Service Letter. Changes have been made to the Mail Codes, and the Parts Needed.
TERMINATION DATE
January 31, 2005PROBLEM
Replace failed HEUI injectors on certain 3412E powered 773D Off-Highway Trucks. On certain machines, the 1388754,1388756, 1590835, 1590836, 1747526/">1747526, 1747527 or earlier Injectors may experience a failure. This can be caused either by:- An individual injector failure, which can be repaired by replacing only the failed injector.
- Excessive injector poppet valve oil leakage on multiple fuel injectors, which can be repaired by replacing a complete set of injectors and software (and possible FLS/FTS reset).
Or
AFFECTED PRODUCT
Use the Machine S/N Range for the affected injector build period in this service program as shown in the table below.
Model |
Identification Number |
Engine S/N Range |
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7FZ73-227
BGL73-111 |
IDX1-211
IDX154-211 |
PARTS NEEDED
A conversion involves the replacement of the full set of injector and a software update. Individual injectors may still be replaced. The troubleshooting tests (see attached rework procedure) should be used in order to determine the repair method.NOTE: Verify that the software listed in Table 2 is available before you start to convert the fuel system. The latest software will be available through the Caterpillar Service Information System.
Table 1 ? Replacement of individual injectors |
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Qty |
Part Number |
Description |
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1747526 | INJECTOR GP |
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1167221 | SEAL |
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1167222 | SEAL |
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9X7681 | SEAL |
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3E6747 | SEAL |
For replacement of complete set of failed injectors-
The parts required for complete update is noted in the list below.
Table 2 ? Conversion of full sets |
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Qty |
Part Number |
Description |
1 per cylinder | 1984752 | INJECTOR GP |
1 | 2143347 | SOFTWARE |
2 per cylinder | 1167221 | SEAL |
1 per cylinder | 1167222 | SEAL |
1 per cylinder | 9X7681 | SEAL |
1 per cylinder | 3E6747 | SEAL |
ACTION REQUIRED
See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
If individual injectors are replaced on 3412E machines:
Product smu/age whichever comes first |
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Parts |
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0-48 mos |
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0-48 mos |
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If complete injector sets are replaced on 3412E machines:
Product smu/age whichever comes first |
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Parts |
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0-48 mos |
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0-48 mos |
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PARTS DISPOSITION
NACD Dealers, return Injector(s) to:Attn: Fergal O?Shea ? PS50599
Service Claims Room
8201 N. University
Peoria, IL 61615
Attach. (1-Rework Procedure)
Rework Procedure
- Use "Test for Cylinder Cutout" to determine if individual injector replacements (using original injector part) are needed.
- Use "Test for Leakage from Poppet Valve" to determine if full injector sets (using new injector parts and software change) are appropriate for repair.
Test for Cylinder Cutout:
- Warm the engine out of Cold Mode.
- Connect Caterpillar Electronic Technician (ET) to the engine while the engine is running.
- Ensure that the engine speed is 1200 rpm +/- 125 rpm. An extremely rough running engine will need to be diagnosed by other methods.
- Cut out one bank of cylinders. Note the engine rpm and the fuel position on the ET screen at that time.
- Cut out one of the remaining cylinders from the cylinder bank that is running. Allow the engine to stabilize and note the fuel position.
- Give power back to that cylinder. Allow the engine to stabilize and note the fuel position.
- Repeat steps 5 through 6 until the cylinder bank has been completely checked.
- Power all cylinders. Allow the engine to stabilize.
- Cut out the other cylinder bank and repeat steps 5 through 8.
- Repeat steps 4 through 9 with the engine at 2000 rpm.
- Compare the results from the fuel position from each cylinder.
- If the cylinder was cut out and the fuel position did not change, the cylinder may not have producing power. This cylinder would be suspect.
- When you are finished with the test, decrease engine rpm to low idle and shut the engine off.
- Replace any suspect injector with a similar original injector. Install new seals for the injector and the jumper tube during this repair. The injector repair procedure is found in Special Instruction REHS0116.
NOTE: It is also possible that multiple injectors are functioning improperly. Complete "Test for Leakage from Poppet Valve" in order to evaluate potential excessive injector leakage and need for fuel system conversion.
Test for Leakage from Poppet Valve:
- Warm engine out of Cold Mode to normal operating temperature.
- Turn off the engine.
- Remove the valve cover bolts in preparation to observe the injectors. Leave covers in place.
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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. |
- Restart the engine and run at low idle with no load.
- Use the ET service tool in order to perform the override test for the injection actuation system. Increase injection actuation pressure to the maximum value.
- Observe all of the injectors under each valve cover for leakage at the spill port. A small amount of dripping is acceptable. However, a continuous stream of oil is an indication of excessive leakage of the poppet valve. Only leaks at the spill port are an indication of excessive poppet valve leakage.
- If multiple injectors are discovered with excessive leakage from the poppet valve, update the full set of injectors and software. Install new seals for the injector and the jumper tube during this repair. The injector repair procedure can be found in Special Instruction REHS0116. The old software part number should be documented for potential future reference. A password from the factory and a different interlock code must be generated for the software update on the ECM.