TERMINATION DATE

PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

including 1313098, 1388754, 1388755, 1388756, 1590835, 1590838, 1747526, 1747527, 1757528, 0R0815, 0R8624, 0R9420 or earlier Injectors, use the following parts;
 

For replacement of complete set of failed injectors ?

The parts required for complete update of 8 cylinder or 12 cylinder engines is noted in the list below.
 

ACTION REQUIRED

SERVICE CLAIM ALLOWANCES

If complete injector sets are replaced on 3408E machines:
 

If complete injector sets are replaced on 3412E machines:
 

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

The two tests below provide the appropriate injector troubleshooting and repair steps for injector updates.

1. Use "Test for Cylinder Cutout" to determine if individual injector replacements (using original injector part) are needed.
2. Use "Test for Leakage from Poppet Valve" to determine if full injector sets (using new injector parts and software change) are appropriate for repair.

1. Warm the engine out of Cold Mode.
2. Connect Caterpillar Electronic Technician (ET) to the engine while the engine is running.
3. Ensure that the engine speed is 1200 rpm +/- 125 rpm. An extremely rough running engine well need to be diagnosed by other methods.
4. Cut out one bank of cylinders. Note engine rpm and the fuel position on the ET screen at that time.
5. Cut out one of the remaining cylinders from the cylinder bank that is running. Allow the engine to stabilize and note the fuel position.
6. Give power back to that cylinder. Allow the engine to stabilize and note the fuel position.
7. Repeat steps 5 through 6 until the cylinder bank has been completely checked.
8. Power all cylinders. Allow the engine to stabilize.
9. Cut out the other cylinder bank and repeat steps 5 through 8.
10. Repeat steps 4 through 9 with the engine at 2000 rpm.
11. Compare the results from the fuel position from each cylinder.
12. 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.
13. When you are finished with the test, decrease engine rpm to low idle and shut the engine off.
14. 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.

Test for Leakage from Poppet Valve:

1. Warm engine out of Cold Mode to normal operating temperature.
2. Turn off the engine.
3. Remove the valve cover bolts in preparation to observe the injectors. Leave covers in place.

4. Restart the engine and run at low idle with no load.
5. 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.
6. 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.
7. If multiple injectors are discovered with excessive leakage from the poppet valve, update the full set of injectors and software with new version given in Special Instruction article REHS1385. 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. Some machines will require a FLS/FTS reset for the proper setting of the fuel flow.