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:
Steering Column Needs To Be Inspected On Certain 769D, 771D, 773D, 775D, 785C, 789C, And 793C Trucks Steering Column Needs To Be Inspected On Certain 769D, 771D, 773D, 775D, 785C, 789C, And 793C Trucks
Engine Emission Labels And An Owner Notification Letter Will Be Provided to Owners Of Certain 914G Wheel Loaders And IT14G Integrated Tool Carriers Engine Emission Labels And An Owner Notification Letter Will Be Provided to Owners Of Certain 914G Wheel Loaders And IT14G Integrated Tool Carriers
Service Letter Cancellation Service Letter Cancellation
Product Support Program For Replacing The Fuel Nozzles On Certain D25D, D30D, D250E, D300E, Articulated Trucks; Challenger 65D Agricultural Tractors; 970F Wheel Loaders; And 615C Scrapers Product Support Program For Replacing The Fuel Nozzles On Certain D25D, D30D, D250E, D300E, Articulated Trucks; Challenger 65D Agricultural Tractors; 970F Wheel Loaders; And 615C Scrapers
Product Support Program For Auger Frame Movement Due To Cylinder Location On Certain AP-1000B, AP-1050B, And AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-245C, BG-260C, And BG-2455C Asphalt Pavers Manufactured By Caterpillar Product Support Program For Auger Frame Movement Due To Cylinder Location On Certain AP-1000B, AP-1050B, And AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-245C, BG-260C, And BG-2455C Asphalt Pavers Manufactured By Caterpillar
Product Support Program For Replacing The Transmission Shift Control On Certain 120H, 135H, 140H, 143H, 160H, 163H, 12H, And 24H Motor Graders Product Support Program For Replacing The Transmission Shift Control On Certain 120H, 135H, 140H, 143H, 160H, 163H, 12H, And 24H Motor Graders
Product Support Program For Updating The MPC-10 Material Module Update On Certain AP-650B, AP-1000B, AP-1050B, And AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-225C, BG-245C, BG-260C, And BG-2455C Asphalt Pavers Manufactured By Caterpilla Product Support Program For Updating The MPC-10 Material Module Update On Certain AP-650B, AP-1000B, AP-1050B, And AP-1055B Asphalt Pavers; And On Certain Barber-Greene BG-225C, BG-245C, BG-260C, And BG-2455C Asphalt Pavers Manufactured By Caterpilla
144-5395 Brake Drum Assemblies Need To Be Removed From Dealer Parts Stock 144-5395 Brake Drum Assemblies Need To Be Removed From Dealer Parts Stock
Product Support Program For Updating Alternator And Air Conditioning Belt Drives On Certain IT38G And IT62G Toolcarriers; 938G, 950G, And 962G Wheel Loaders Product Support Program For Updating Alternator And Air Conditioning Belt Drives On Certain IT38G And IT62G Toolcarriers; 938G, 950G, And 962G Wheel Loaders
PSP TO REPLACE CYLINDER PACKS ON CERTAIN D8R TRACK-TYPE TRACTORS AND 583R PIPELAYERS TO REDUCE OIL CONSUMPTION - PS5 557 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01 PSP TO REPLACE CYLINDER PACKS ON CERTAIN D8R TRACK-TYPE TRACTORS AND 583R PIPELAYERS TO REDUCE OIL CONSUMPTION - PS5 557 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01
PSP TO REPLACE CYLINDER PACKS ON CERTAIN D8R TRACK-TYPE TRACTORS AND 583R PIPELAYERS BECAUSE OF PISTON DEBONDING - PS5 590 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01 PSP TO REPLACE CYLINDER PACKS ON CERTAIN D8R TRACK-TYPE TRACTORS AND 583R PIPELAYERS BECAUSE OF PISTON DEBONDING - PS5 590 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/01
PSP TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS TO REDUCE OIL CONSUMPTION - PS5 591 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/2001 PSP TO REPLACE CYLINDER PACKS ON CERTAIN 980G WHEEL LOADERS; 824G, 825G, AND 826G COMPACTORS TO REDUCE OIL CONSUMPTION - PS5 591 - MAILED US AND CANADA, CACO, COFA, CAPL, CCL, COSA - REVISED 03/2001
Product Support Program For Adding A Larger Fan To Improve The Cooling System On Certain 574 And 1088 XLC Forwarders Product Support Program For Adding A Larger Fan To Improve The Cooling System On Certain 574 And 1088 XLC Forwarders
Product Support Program For Installing A New Rear Window Latch Striker On Certain CH65E, CH75E, CH85E, And CH95E Challenger Tractors Product Support Program For Installing A New Rear Window Latch Striker On Certain CH65E, CH75E, CH85E, And CH95E Challenger Tractors
Product Support Program For Replacing The Drive Wheel Backup Ring Segments And Tightening The Axle Shaft Bolts On Certain CH65E, CH75E, CH85E, And CH95E Challenger Tractors Product Support Program For Replacing The Drive Wheel Backup Ring Segments And Tightening The Axle Shaft Bolts On Certain CH65E, CH75E, CH85E, And CH95E Challenger Tractors
Product Support Program For Installing A Rubber Hood Baffle On Certain CH65E, CH75E, CH85E, And CH95E Challenger Tractors Product Support Program For Installing A Rubber Hood Baffle On Certain CH65E, CH75E, CH85E, And CH95E Challenger Tractors
Product Support Program For Reworking The Brake Pedal Pivot Pin On Certain IT18F, IT24F And IT28F Toolcarriers And 918F, 924F And 928F Wheel Loaders Product Support Program For Reworking The Brake Pedal Pivot Pin On Certain IT18F, IT24F And IT28F Toolcarriers And 918F, 924F And 928F Wheel Loaders
Product Support Program For Replacing The Turbochargers On Certain 777D Off-Highway Trucks Product Support Program For Replacing The Turbochargers On Certain 777D Off-Highway Trucks
PRODUCT SUPPORT PROGRAM FOR DIRECTIONAL CLUTCH FAILURES ON CERTAIN 12H, 120H, 135H, 140H, 143H, 160H, AND 163H MOTOR GRADERS PRODUCT SUPPORT PROGRAM FOR DIRECTIONAL CLUTCH FAILURES ON CERTAIN 12H, 120H, 135H, 140H, 143H, 160H, AND 163H MOTOR GRADERS
A Suction Fan Kit Needs To Be Added To The Rotary Air Screen On The Cooling System On Certain Lexion 465 And Lexion 485 Combines A Suction Fan Kit Needs To Be Added To The Rotary Air Screen On The Cooling System On Certain Lexion 465 And Lexion 485 Combines
Engine Improvements Need To Be Performed On Certain Lexion 450, Lexion 460, And Lexion 465 Combines Engine Improvements Need To Be Performed On Certain Lexion 450, Lexion 460, And Lexion 465 Combines
Product Support Program For Replacing The Water Pump On Certain 416C, 426C, And 436C Backhoe Loaders Product Support Program For Replacing The Water Pump On Certain 416C, 426C, And 436C Backhoe Loaders
A Locking Collar Needs To Be Added To The Connection Between The Aps Concave Frame And The Main Threshing Concave Frame On Certain Lexion 450, Lexion 460, Lexion 465, Lexion 480, And Lexion 485 Combines A Locking Collar Needs To Be Added To The Connection Between The Aps Concave Frame And The Main Threshing Concave Frame On Certain Lexion 450, Lexion 460, Lexion 465, Lexion 480, And Lexion 485 Combines
Product Support Program Installing A New Swing Pinion Axle To Reduce Noise From The Swing Drive On Certain 550, 570 And 580 Harvesters Product Support Program Installing A New Swing Pinion Axle To Reduce Noise From The Swing Drive On Certain 550, 570 And 580 Harvesters