PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES -
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PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PS0456 - US, CANADA, CACO, LTD COFA - REVISED 10/90
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.
(Revised October 1990) U-130 A-88 AU-86.1 1100, 1290 PS0456 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 "PS0456" as Part Number, "7755" as Group Number, and "96" as Description Code. NOTE: If this Program is administered on E200B or EL200B Excavators, it is recommended that the June 22, 1990 Service Letter - PS4442 be done at the same time. NOTE: This Revised Service Letter replaces the June 25, 1990 Service Letter. Changes have been made to add Affected Product.
Termination Date
June 30, 1991
Problem
The fuel injector sleeves in the cylinder head of certain IT14B Integrated Toolcarriers; E110B, E120B, E200B, EL200B, 213B, 214B, 224B, E240B, and EL240B Excavators; 446 Backhoe Loaders; CB-434, CP-563, and CS-563 Compactors; AP-1050 Asphalt Pavers; and 3114 and 3116 Industrial and Generator Set Engines are subject to pitting and erosion due to fuel cavitation between the injector and the sleeve. The sleeves may pit or crack through, allowing fuel to contaminate the coolant. Coolant contaminated with fuel may also damage the radiator and coolant hoses.
Affected Product
Model Identification Number IT14B 3NJ1-42 E110B 8MF1-151 E120B 6JF1-212 E200B* 6KF1-439 6KG1-249 EL200B* 7DF1-986 213B 1EJ1-233, 236-245, 247, 248 214B 4CF1-261, 263, 265-275, 278 9MF1-171, 173-182, 185 224B 7WF1-47, 51, 56, 65 E240B 8SF1-36 9PF1-196 EL240B 5WG1-166 6MG1-104 CB-434 3TF35-37, 39-41, 45-49, 52 446 6XF1-227 CP-563 1YJ56-59 CS-563 8XF45-50, 57 AP-1050 1JG46-48 3114 5EF1-675 6AF1-581 3114 1ZG1-432 5JG1-743 3116 2SG1-936 2WG1-859 4PG1-611 1NJ1-999 * NOTE: The E200B and EL200B Excavators need to be updated to a new injector design released for that machine. The new injectors have a different orifice size to help eliminate black smoke problems reported on some earlier machines. When replacing injectors on E200B and EL200B Excavators, use injector part number 7E8729 if available. Reset the fuel setting and timing if the injectors are available. See Action Required. Also, install a fuel hand priming pump and primary filter per the June 22, 1990 Service Letter - PS4442.
Parts Needed
Affected Product equipped with 3114 Engines 4 - Injector (Use the appropriate new or remanufactured parts for your rating) 1 - 7W9955 Gasket (cylinder head) 1 - 7W8903 Gasket (inlet manifold) 2 - 7E8772 Gasket (exhaust manifold) 1 - ( ** ) Head-Cylinder (Use the appropriate new or remanufactured parts for your rating) 2 - 2M6471 Plug-cup 3 - 1J9671 Seal O-ring 3 - 9S8003 Plug O-ring - *** Hoses - Radiator-Regulator Housing-Aftercooler Affected Product equipped with 3116 Engines 6 - Injector (Use the appropriate new or remanufactured parts for your rating) 1 - 7W9956 Gasket (cylinder head) 1 - 7W5626 Gasket (inlet manifold) 3 - 7E8772 Gasket (exhaust manifold) 1 - ( ** ) Head-Cylinder (Use the appropriate new or remanufactured parts for your rating) 2 - 2M6471 Plug-cup 3 - 1J9671 Seal O-ring 3 - 9S8003 Plug O-ring - *** Hoses - Radiator-Regulator Housing-Aftercooler * Former Remanufactured New Remanufactured Injector Injector Injector Injector P/N P/N P/N P/N -------------------------------------------------------------- 7C2072 0R2745 7E8727 0R3002 9Y2462 0R2745 7E8727 0R3002 9Y4982 0R2745 7E8727 0R3002 -------------------------------------------------------------- 9Y3113 0R2803 7E8728 0R3003 ------ ------ 7E8729 ------ NOTE: Positive identification of the unit injectors can be made by part number only. Part numbers are found on either the hold down clamp or the spring retainer. New versions of injectors have improved edge filters and o-ring tip seals for improved combustion gas sealing. The new versions can be distinguished from the former version by the smooth sided edge filter on the pump body and the o-ring seal on the tip. Former versions have a ribbed edge filter and no provisions for an o-ring tip seal. All injectors in an engine must be of the same version. All injectors will be used in the remanufacturing process. ** You may decide to replace the injector sleeves in the cylinder head instead of exchanging the head. If you do so, the following parts, tools and instructions are needed: 6 - 7W5749 Sleeve (order 4 for a 3114 Engine) 1 - 4C4462 Tool Group (for removal and installation of injector sleeves) 1 - SEHS9120 "Removal And Installation Of Unit Injector Sleeve" If a Remanufactured Cylinder Head is desired, refer to the following list: ENGINE UPGRADE REMANUFACTURED DESCRIPTION *REF NEW P/N TO NEW P/N P/N 3114 0R2842 0R2743 CYL. HEAD GP. 4W3814, 9Y8849 3114 0R2841 0R2742 CYL. HEAD AS. 7W5664, 9Y6164 3116 0R2840 0R2730 CYL. HEAD GP. 4W0737, 9Y8850 3116 0R2839 0R2729 CYL. HEAD AS. 7W3278, 9Y6166 *For use only if Remanufactured P/N is not available. *** Check the parts book for your engine to determine the specific coolantho se t numbers for your application. All hoses that have been in contact with fuel contaminated coolant should be replaced.
Action Required
Follow the procedures in the Service Manual. Remove and install the cylinder head and injectors. Synchronize the injectors, adjust the fuel setting, fuel timing, and valve lash. On E200B and EL200B Excavators only, preform the following steps. Replace the existing Injector Groups with the new 7E8729 Injector Groups, if available. Follow the procedures in the Service Manual along with the following steps to install the new injectors. Specifications on the existing Engine Information Plate need to be updated, as shown below. 1. Remove the fuel injectors in accordance with the procedures shown in the Service Manuals. 2. Clean the inside of the 7W5479 Injector Sleeves with solvent and 4C5553 Sleeve Cleaning Brush, if necessary. NOTE: 4C5553 Sleeve Cleaning Brush itself is available in the parts system. And it is also included in the 4C4462 Tool Group for "Removal and Installation of Unit Injector Sleeve". See Special Instruction Form SEHS9120. 3. Install new 7E8729 Fuel Injector Groups in accordance with the procedures shown in the Service Manuals. 4. Adjust Injector Synchronization, Fuel Setting, Fuel Timing and Valve Lash, in accordance with the procedures in the Service Manual. New specifications for the Fuel Timing and the Fuel Setting are as follows: New Fuel Timing: 64.11 +/- 0.05 mm (+/- 0.20 mm for checking) New Fuel Setting: 8.31 mm 5. Stamp the new specifications of Fuel Setting and Fuel Timing on the new 4W5140 Plate. After the information has been stamped on the new plate, install the new plate over the existing engine information plate, with the engine serial number still visible. NOTE: The other specifications except "Fuel Setting" and "Fuel Timing" have not been changed, but must be stamped on the new plate.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (C/L) (Sell) comes first Affected Product equipped with 3114 Engines 0-3000 100% 5 0 5 0 0 0-24 mo 3001-5000 33 1/3% 2.5 0 2.5 50% 5 25-36 mo NOTE: This is a 10-hour job. Affected Product equipped with 3116 Engines 0-3000 100% 6 0 6 0 0 0-24 mo 3001-5000 33 1/3% 3 0 3 50% 6 25-36 mo NOTE: This is a 12-hour job.
Parts Disposition
Any parts removed (with the exception of cores used for Caterpillar Remanufactured parts) can be rendered useless and scrapped immediately upon completion of the repair.
Caterpillar Information System:
PSP FOR INSTALLING A HAND PRIMING PUMP, PRIMARY FUEL FILTER, AND RETURN LINE CHECK VALVE ON CERTAIN E200B AND EL200B EXC AVATORS - PS4442 - MAILED CFEL PSP FOR INSTALLING A HAND PRIMING PUMP, PRIMARY FUEL FILTER, AND RETURN LINE CHECK VALVE ON CERTAIN E200B AND EL200B EXC AVATORS - PS4442 - MAILED CFEL
PSP FOR INSTALLING A HAND PRIMING PUMP, PRIMARY FUEL FILTER, AND RETURN LINE CHECK VALVE ON CERTAIN E200B AND EL200B EXC AVATORS - PS4442 - MAILED US AND CANADA, CACO, COFA PSP FOR INSTALLING A HAND PRIMING PUMP, PRIMARY FUEL FILTER, AND RETURN LINE CHECK VALVE ON CERTAIN E200B AND EL200B EXC AVATORS - PS4442 - MAILED US AND CANADA, CACO, COFA
Product Support Program For Cylinder Head Gasket Failures On Certain D6D, D6H, D7G, And D7H Tractors; 12G, 14G, And 140G Motor Graders; D25C, D25D, D30C, D30D, D35C, D250B, D300B, D350C, And D350D Articulated Dump Trucks; Challenger 65 Tractors; Product Support Program For Cylinder Head Gasket Failures On Certain D6D, D6H, D7G, And D7H Tractors; 12G, 14G, And 140G Motor Graders; D25C, D25D, D30C, D30D, D35C, D250B, D300B, D350C, And D350D Articulated Dump Trucks; Challenger 65 Tractors;
SERVICE LETTER EXTENSION FOR NOVEMBER 27, 1989 SL - PS4404 - PSP FOR REPLACING THE 8R0944 HOSE ASSEMBLIES IN THE PILOT OPE RATED HYDRAULIC CONTROL GROUP ON CERTAIN 225B, 227, 229, 235C, AND 245B EXCAVATORS - MAILED US AND CANADA SERVICE LETTER EXTENSION FOR NOVEMBER 27, 1989 SL - PS4404 - PSP FOR REPLACING THE 8R0944 HOSE ASSEMBLIES IN THE PILOT OPE RATED HYDRAULIC CONTROL GROUP ON CERTAIN 225B, 227, 229, 235C, AND 245B EXCAVATORS - MAILED US AND CANADA
Product Support Program For Multiple Track Pin Breakage On 215B SA, 219, 225B, 225B LC, And 225D Excavators Product Support Program For Multiple Track Pin Breakage On 215B SA, 219, 225B, 225B LC, And 225D Excavators
PSP FOR INSTALLING NEW PUMP DRIVE COOLER ON CERTAIN 245 AND 245B EXCAVATORS - PS4483 - MAILED US AND CANADA, CACO, COFA, CFE L, COSA, LIMITED BRAZIL PSP FOR INSTALLING NEW PUMP DRIVE COOLER ON CERTAIN 245 AND 245B EXCAVATORS - PS4483 - MAILED US AND CANADA, CACO, COFA, CFE L, COSA, LIMITED BRAZIL
PSP FOR FINAL DRIVE SPROCKETS ON CERTAIN 215C EXCAVATORS - PS0445 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA PSP FOR FINAL DRIVE SPROCKETS ON CERTAIN 215C EXCAVATORS - PS0445 - MAILED US AND CANADA, CACO, CFEL, COSA, LIMITED COFA
SERVICE LETTER EXTENSION FOR PSP FOR REWORKING THE ENGINE SUPPORT, MOUNT AND STRUTS ON CERTAIN 245 EXCAVATORS - PS4319 - MAI LED US AND CANADA, CACO, COFA, CFEL SERVICE LETTER EXTENSION FOR PSP FOR REWORKING THE ENGINE SUPPORT, MOUNT AND STRUTS ON CERTAIN 245 EXCAVATORS - PS4319 - MAI LED US AND CANADA, CACO, COFA, CFEL
SERVICE LETTER EXTENSION FOR MAY 13, 1989 SL - PS4337 - PSP FOR REPLACING THE STICK CYLINDER ROD RETAINING WASHER ON CER TAIN 225, 225B, 225B LC, AND 229 EXCAVATORS; AND 227 LOGGERS - MAILED US AND CANADA, CACO, COFA, COSA SERVICE LETTER EXTENSION FOR MAY 13, 1989 SL - PS4337 - PSP FOR REPLACING THE STICK CYLINDER ROD RETAINING WASHER ON CER TAIN 225, 225B, 225B LC, AND 229 EXCAVATORS; AND 227 LOGGERS - MAILED US AND CANADA, CACO, COFA, COSA
SERVICE LETTER SUPPLEMENT FOR MARCH 28, 1990 SL - PI3461 - PRIORITY - THE UPPER FRAME NEEDS TO BE REINFORCED ON CERTAIN 225 D AND 229D EXCAVATORS - MAILED US AND CANADA, CACO CFEL, COSA, LIMITED COFA SERVICE LETTER SUPPLEMENT FOR MARCH 28, 1990 SL - PI3461 - PRIORITY - THE UPPER FRAME NEEDS TO BE REINFORCED ON CERTAIN 225 D AND 229D EXCAVATORS - MAILED US AND CANADA, CACO CFEL, COSA, LIMITED COFA
Product Support Program For Installing A New Swing Gear Pinion And Swing Bearing In Certain E300 And EL300 Excavators Product Support Program For Installing A New Swing Gear Pinion And Swing Bearing In Certain E300 And EL300 Excavators
PARTS STOCK ACTION ONLY - 8D6947 AND 9G5589 SWITCHES NEED TO BE REMOVED FROM PARTS STOCK - PI7234 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA PARTS STOCK ACTION ONLY - 8D6947 AND 9G5589 SWITCHES NEED TO BE REMOVED FROM PARTS STOCK - PI7234 - MAILED US AND CANADA, CAC O, COFA, BRAZIL, CFEL, COSA
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; 213B, 214B, AND 224B EXC AVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET ENGINES - PS0456 - MAILED COSA PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; 213B, 214B, AND 224B EXC AVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET ENGINES - PS0456 - MAILED COSA
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES -
PSP FOR IMPROVING TRAVEL MODULATION, JERKY STEERING, AND/OR TRAVEL DRIFT PROBLEMS ON CERTAIN 235C EXCAVATORS - PS0468 - MAI LED US AND CANADA, COSA PSP FOR IMPROVING TRAVEL MODULATION, JERKY STEERING, AND/OR TRAVEL DRIFT PROBLEMS ON CERTAIN 235C EXCAVATORS - PS0468 - MAI LED US AND CANADA, COSA
SERVICE LETTER SUPPLEMENT FOR JUNE 1, 1990 SL - PSP FOR REPAIRING STICK PIVOT BORE ELONGATION ON CERTAIN 231D EXC AVATORS - PS0461 - MAILED US AND CANADA SERVICE LETTER SUPPLEMENT FOR JUNE 1, 1990 SL - PSP FOR REPAIRING STICK PIVOT BORE ELONGATION ON CERTAIN 231D EXC AVATORS - PS0461 - MAILED US AND CANADA
PSP FOR REDUCING BLACK SMOKE ON CERTAIN E200B AND EL200B EXCAVATORS - PS0466 - MAILED US AND CANADA, CACO PSP FOR REDUCING BLACK SMOKE ON CERTAIN E200B AND EL200B EXCAVATORS - PS0466 - MAILED US AND CANADA, CACO
PSP FOR REDUCING BLACK SMOKE ON CERTAIN E200B AND EL200B EXCAVATORS - PS0466 - MAILED US AND CANADA, CACO PSP FOR REDUCING BLACK SMOKE ON CERTAIN E200B AND EL200B EXCAVATORS - PS0466 - MAILED US AND CANADA, CACO
PSP FOR INSTALLING NEW CLAMPS TO SECURE THE STARTER CABLES AND FUEL HOSE ON CERTAIN E70B EXCAVATORS PSP FOR INSTALLING NEW CLAMPS TO SECURE THE STARTER CABLES AND FUEL HOSE ON CERTAIN E70B EXCAVATORS
Product Support Program For Replacing Failed Cylinder Head Gaskets On Certain D8L, D8N, D9N, And D10N Tractors; 16G Motor Graders; D35HP, D40D, D400, And D400D Articulated Dump Trucks; 245, And 245B Excavators; 589 Pipelayers; 621E, 623E, 627E, 631E, Product Support Program For Replacing Failed Cylinder Head Gaskets On Certain D8L, D8N, D9N, And D10N Tractors; 16G Motor Graders; D35HP, D40D, D400, And D400D Articulated Dump Trucks; 245, And 245B Excavators; 589 Pipelayers; 621E, 623E, 627E, 631E,
Product Support Program For Replacing Failed Cylinder Head Gaskets On Certain D8L, D8N, D9N, And D10N Tractors; 16G Motor Graders; D35HP, D40D, D400, And D400D Articulated Dump Trucks; 245, And 245B Excavators; 589 Pipelayers; 621E 623E, 627E, 631E, Product Support Program For Replacing Failed Cylinder Head Gaskets On Certain D8L, D8N, D9N, And D10N Tractors; 16G Motor Graders; D35HP, D40D, D400, And D400D Articulated Dump Trucks; 245, And 245B Excavators; 589 Pipelayers; 621E 623E, 627E, 631E,
PSP FOR INSTALLING A CHECK VALVE IN THE FUEL FILTER LINES GROUP ON CERTAIN E110B, E120B, E200B, EL200B, 213B, 314B, 224B, E2 40B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 GENERATOR SET, INDUSTRIAL, AND MARINE ENGINES - PS0472 - MAILE PSP FOR INSTALLING A CHECK VALVE IN THE FUEL FILTER LINES GROUP ON CERTAIN E110B, E120B, E200B, EL200B, 213B, 314B, 224B, E2 40B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 GENERATOR SET, INDUSTRIAL, AND MARINE ENGINES - PS0472 - MAILE
PSP FOR REPLACING THE FAN BELT TIGHTENER ON CERTAIN 225D AND 231D EXCAVATORS - PS4524 - MAILED US AND CANADA, CACO, CFEL - REV ISED 01/91 PSP FOR REPLACING THE FAN BELT TIGHTENER ON CERTAIN 225D AND 231D EXCAVATORS - PS4524 - MAILED US AND CANADA, CACO, CFEL - REV ISED 01/91
PSP FOR MULTIPLE TRACK PIN BREAKAGE ON 215B SA, 219, 225B, 225B LC, AND 225D EXCAVATORS - PS0454 - MAILED CACO PSP FOR MULTIPLE TRACK PIN BREAKAGE ON 215B SA, 219, 225B, 225B LC, AND 225D EXCAVATORS - PS0454 - MAILED CACO