Product Support Program For Replacing Fuel Injectors Due To Excessive Oil Consumption On Certain 3116 And 3126 HEUI 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 only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5331" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

Problem

Some 3116 and 3126 HEUI Engines may have excessive oil consumption as a result of oil leaking past the intensifier piston o-ring inside the injector. Engine oil consumption becomes excessive and may increase rapidly. There are no traditional signs of oil consumption, smoke, blow-by, etc. The engine has no performance problem, has good power and normal exhaust smoke.

NOTE: The problem seems to be very low frequency and is not batch related.

Affected Product
Model & Identification Number

3116 (8WL1-Up)

3126 (1WM1-Up 4ES1-Up )

Parts Needed

3116 Engines

6 - 1162784 Injectors (for 170 Hp)

6 - 1166706 Injectors (for 185, 195, 215, 230, 250 and 275 Hp)

3126 Engines

6 - 0R4970 Injectors (for 230, 250, 275, 300 and 330 Hp)

6 - 0R4972 Injectors (for 175, 190 and 210 Hp)

Action Required

See the attached rework procedure.

Service Claim Allowances

Labor Hour Breakdown

TK = TopKick

MC = Medium Hood Conventional

Claim 1290-500 for an additional 1.6 hours if the repair is made in a motor home chassis, cab type (RV), or bus chassis, cab type (BU).

Parts Disposition

TEPS/MEPS Dealers must return the affected part(s) to their Caterpillar dealer.

Parts must be returned undamaged in the original shipping boxes to:

Injectors must be sealed in a plastic bag to prevent fuel from leaking out during shipment.

A clear, legible copy of the service report in a plastic page protector must be included in the box with the returned injectors. The report must be packaged to arrive free of oil, grease and diesel fuel.

Attach.

(1 - Rework Procedure)

Rework Procedure

Check to see if PS8826 (Jumper-tube Rework) is to be applied to the affected engine. Perform PS8826 if it has not been performed prior to oil consumption test.

Document the oil consumption for 30 days using the attached Oil Consumption Test Sheet, Form Number 01-081227.

All of the following steps must be followed in order to establish base line data for oil consumption for full warranty reimbursement.

1. Change oil and filter at the beginning of the test to establish base line at normal change interval. Use CG-4 oil and new oil filter.

NOTE: Oil and filter are not claimable under this letter.

2. Refill with the proper amount of oil; 27liters/29 quarts, and 18 liters/19 quarts per the July 1997 Operations Maintenance Manual.

3. Inspect for external leaks around the gaskets and the front and rear main seals.

4. Inspect the air compressor air tanks for excess oil.

5. Inspect the turbo oil drain line for excessive oil indicating seal leak.

6. At the completion of the 30 day test, determine if oil consumption is excessive using either of the following criteria:

A) Oil consumption has doubled or tripled over a short period of time from the historical oil usage of the engine in question.

B) Oil consumption is 2 to 3 times that of other engines in similar applications.

NOTE: Normal oil consumption varies widely with duty cycles may use 1 gallon of oil per 100 gallons of fuel. Small changes in oil consumption, (1 to 2 quarts per oil change) are not a cause for concern.

7. If no other causes of oil consumption can be found, call Caterpillar to obtain authorization to replace all (6) injectors. Call one of the following during the hours of 7:00 am through 5:00 pm.

8. Be prepared to discuss degree of oil consumption and diagnostics performed with the above personnel. Have documentation ready at the time of call.

9. If diagnostics have been performed and documentation indicates excessive oil consumption, the above personnel will issue an authorization number. You must include the following on warranty claim and service report:

Date Called

Authorization Number

Name of Person Issuing Authorization

Serial Number of each Injector Replaced

Oil Consumption Test Report (front side), Form 01-081227

Illustration 1

Oil Consumption Test Report (back side), Form 01-081227

Illustration 2