Product Support Program For Replacing The Hydraulic Jumper Tubes And Injectors On Certain HEUI Truck Engines Caterpillar

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 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 "PS8544" 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.

NOTE: This Revised Service Letter replaces the January 4, 1996 Service Letter. Changes have been made to the Problem, Affected Product, Parts Needed, Action Required.

Termination Date

Problem

Group 1

Certain 3126 HEUI Truck Engines may have some 1249714 Jumper Tube Assemblies that crack at the junction of the tube body and the flare at the injector end.This crack could propagate to a point where a hydraulic oil leak will shut down the engine.The warning signals are multiple 164-11 Events, hard hot starting, low power, and/or an inability to have the actual hydraulic oil pressure equal the desired hydraulic oil pressure when running the Injection Actuation Pressure Test on a warm engine.Hold-down clamps are also being replaced to allow access to the flange screws and eliminate the need for service tool 1252583/">1252583.

The engines with serial numbers 1WM2133-2485 were built with the improved jumper tubes, but these tubes may have been installed with insufficient torque on the clamp bolt. The result could be a failure of the jumper tube. These engines do not need new 1136145 Seats or 1265424 Clamps. Both of these components can be reused. Otherwise the engines should be treated like serial numbers 1WM210-2132.

Group 2

Certain 3126 HEUI Truck Engines may have injectors with machining defects which could result in injector failures. These injectors need to be replaced.

Affected Product
Model & Identification Number

Group 1

3126 (1WM210-2485)

Group 2

3126 (1WM250-250, 1WM1621-1621, 1WM1623-1623, 1WM1640-1652, 1WM1654-1670, 1WM1675-1675, 1WM1683-1683 , 1WM1707-1707, 1WM1709-1709, 1WM1685-1685, 1WM1689-1689, 1WM1710-1710, 1WM1724-1724, 1WM1732-1732 , 1WM1739-1739, 1WM1752-1752, 1WM1753-1753, 1WM1755-1755, 1WM1756-1756, 1WM1773-1773, 1WM1775-1775, 1WM1805-1807 , 1WM1821-1895, 1WM1906-1939, 1WM1946-2000, 1WM2001-2028 , 1WM2030-2046, 1WM2052-2052, 1WM2053-2053, 1WM2055-2055, 1WM2059-2059, 1WM2078-2078 , 1WM2079-2079, 1WM2097-2097, 1WM2098-2098, 1WM2103-2103, 1WM2115-2115, 1WM2118-2118, 1WM2122-2122, 1WM2131-2174 , 1WM2179-2179, 1WM2181-2181)

NOTE: Some engine serial numbers fall within Group 1 and Group 2. Those serial numbers will require the rework for both Groups 1 and 2 to be performed.

Parts Needed

Group 1

6 - 1136145 Seat

6 - 1136303 Seal-O-Ring

1 - 1192940 Gasket

6 - 1249714 Tube Assembly

6 - 1265424 Clamp-Injector

Group 2

6 - 0R4970 Injector (for 230 HP and Above)

6 - 0R4972 Injector (for 210 HP and Below)

6 - 1136303 Seal O-Ring (if not included in group 1)

6 - 1148718 Seal O-Ring

1 - 1192940 Gasket (if not included in group 1)

6 - 1231199 Seal

6 - 1258274 Seal O-Ring

Action Required

See attached rework procedure.

Service Claim Allowances

Group 1

Affected Product

NOTE: * After failure repairs made prior to January 1, 1996 should claim actual reasonable time.

* After failure repairs made January 1, 1996 or later should use the 3126 Time Requirement Guide to determine additional labor hours.

* Before failure repair should claim the labor hours listed below:

NOTE: If Group 1 and Group 2 repairs are performed, claim Group 2 SMCS Codes ONLY.

Add an additional 1.6 Hours to both groups 1 and 2 if the procedure is done in a motor home.

Parts Stock

Submit one claim for all 1249714 Tube Assemblies removed from Parts Stock.

NOTE: US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.

NOTE: TEPS/MEPS dealers must return the affected Parts Stock to their Caterpillar dealer for replacement.

Group 2

NOTE: Add an additional 1.6 Hours to both groups 1 and 2 if the procedure is done in a motor home.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Group 1

Affected Product

Jumper Tube Removal

1. Loosen, but do not back off the jumper tube flare nut at the end nearest the high pressure oil manifold, using the 5P0144 Crow's Foot Socket.

2. Remove the 8T0292 Bolt and the fuel injector hold-down clamp.

3. Loosen and back out the #10 Allen head bolts at the fuel injector using the 1252584 Ball Head Hex Drive Bit (4mm). Leave the bolts in the jumper tube flange while removing the jumper tube. Retain the bolts for reassembly.

4. Stabilize the top of the tube with one finger and back out the nut at the mainfold end of the tube.

5. Carefully remove the jumper tube from the fuel injector and oil manifold.

6. Remove the jumper tube seat and O-ring from the top of the fuel injector.

NOTE: A magnet is recommended for picking up the seat.

7. Retain the removed jumper tube, seat, and O-ring until the warranty claim is processed.

Jumper Tube Installation

1. Place a new 1136303 O-Ring into the channel on top of the fuel injector.

NOTE: Do not use STP to lube O-rings. STP traps moisture and will cause rust buildup in the O-ring groove.

2. Place a new 1136145 Jumper Tube Seat over the O-ring on top of the injector.

NOTE: The earlier tubes have a shiny appearance on the two bolt flange. The new tubes have a phosphate and oil coating, which is black, similar in color to an internal engine bolt.

NOTE: The following guidelines should be used to identify parts in the system. The date code on the 1249714 Tube plastic wrapper is in the form 01996476. The first four numbers represent the month and year, for example, 0196 means January 1996. The 1249714 Tubes are considered acceptable if the date code is 1295476 or later. The 1249714 Tubes are considered unacceptable if the date code is 1195476 or earlier. December 1995 represents the cutoff date for acceptable parts.

3. Install the manifold end of a new jumper tube, then position the injector end onto the seat on top of the injector. Start the flare nut into the manifold and tighten by hand until the flare is seated on top of the tuned fitting in the manifold.

4. Install the two #10 Allen head bolts through the flange into the injector and hand tighten until snug.

5. Install the new 1265424 Injector Clamp (which eliminates the need for the 1252583 Service Tool) and 8T0292 Bolt. Tighten the bolt to 36 ± 4 N·m (27 ± 3 lb. ft.). The injector must bottom in the sleeve bore with the jumper tube flange parallel to the injector top surface.

6. Tighten the flare nut at the oil manifold to 40 ± 5 N·m (30 ± 4 lb. ft.). Loosen the nut and tighten again to a torque of 40 ± 5 N·m (30 ± 4 lb. ft.).

7. Tighten each of the two #10 Allen head bolts to a torque of 3 ± 1 N·m (27 ± 9 lb. in.) using the 4 mm ball head hex driver bit.

8. Tighten each #10 Allen head bolt to a torque of 6 ± 1 N·m (54 ± 9 lb. in.).

9. Tighten the 8T0292 Injector Clamp Bolt, installed in Step 5 above, to 36 ± 4 N·m (27 ± 3 lb. ft.).

10. Once the rework is complete, stamp the engine block with the letters "JT".

NOTE: The letters should be stamped on the rail located on the right side of the engine (turbocharger side), near the flywheel housing, five inches up from the oil pan mounting surface and four inches forward from the flywheel housing mount surface. Typically, the serial number is stamped on the horizontal surface of this rail. The letters "JT" should be stamped on the vertical surface.

Motor coaches are installed with the engine facing rear.

Parts Stock

Remove all old 1249714 Tube Assemblies from parts stock. The old tube assemblies will appear shiny in color on the two bolt flange while the new tube assemblies will appear black in color. The following guidelines should be used to identify parts in the system. The date code on the 1249714 Tube plastic wrapper is in the form 01996476. The first four numbers represent the month and year, for example, 0196 means January 1996. The 1249714 Tubes are considered acceptable if the date code is 1295476 or later. The 1249714 Tubes are considered unacceptable if the date code is 1195476 or earlier. December 1995 represents the cutoff date for acceptable parts.

Group 2

Injector Replacement

1. Remove the jumper tubes and rocker stands (4 bolts per stand).

2. Disconnect the injector wiring harness at each injector.

3. Remove the injector. Ream the injector sleeves in cylinder head using the reamer from the 4C4462 or 1273460 Sleeve Tool Group.

4. Install the new injector. Lubricate 1148718 upper and 1258274 lower O-Rings with O-ring lube, or engine oil.

5. Replace the six 1231199 Weatherpak Seals before connecting the wiring harness.

6. Assemble and set valve lash.

7. Install jumper tubes per separate documentation attached.

8. Once the rework is complete, stamp the engine block with the letters "IU".

NOTE: The letters should be stamped on the rail located on the right side of the engine (turbocharger side), near the flywheel housing, five inches up form the oil pan mounting surface and four inches forward from the flywheel housing mount surface. Typically, the serial number is stamped on the horizontal surface of this rail. The letters "IU" should be stamped on the vertical surface.

Motor coaches are installed with the engine facing rear.

Illustration 1

Illustration 2