PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE HIGH PRESSURE OIL LINE AND FITTINGS BETWEEN THE HEUI OIL PUMP AND THE HEAD ON CERTAIN 3126B ENGINES INSTALLED ON FMTV TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE HIGH PRESSURE OIL LINE AND FITTINGS BETWEEN THE HEUI OIL PUMP AND THE HEAD ON CERTAIN 3126B ENGINES INSTALLED ON FMTV TRUCKS

Usage:

SEBE8459

August 6, 2003
U-206

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE HIGH PRESSURE OIL LINE AND FITTINGS BETWEEN THE HEUI OIL PUMP AND THE HEAD ON CERTAIN 3126B ENGINES INSTALLED ON FMTV TRUCKS
1000		PI10250

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI10250" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI10250" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

PROBLEM

The high pressure oil line and fitting between the 3126B HEUI Oil Pump and head may leak engine oil. The oil line needs to be removed and replaced by a new Tube Kit.

AFFECTED PRODUCT

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Model	Identification Number
3126B	6PZ1-2221 7JZ1-5865

PARTS NEEDED

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Qty	Part Number	Description
1	2400716	TUBE KIT

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1.8	0	0	0	0
NOTE: This is a 1.8-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPAIRING THE HIGH PRESSURE OIL LINE AND FITTINGS BETWEEN THE HEUI OIL PUMP AND THE HEAD

MODELS INVOLVED - CERTAIN 3126B ENGINES INSTALLED ON FMTV TRUCKS

Dear Caterpillar Product Owner:

A new tube kit needs to be installed on the products listed below. The high pressure oil line and fitting between the 3126B HEUI Oil Pump and head may leak engine oil and cause a potential fire hazard. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated August 6, 2003 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to August 6, 2003 Service Letter

Rework Procedure

NOTE: The 2400716 tube kit is used in order to replace the flexible high pressure oil line. The oil line is part of the Hydraulic Electronic Unit Injector (HEUI) Pump.

Removal of the Flexible Oil Line

NOTE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Remove any coolant lines that may interfere with the installation. Remove any air inlet lines that may interfere with the installation.

Illustration 1

(1) Bolt

(2) Washer

(3) Air inlet cover

Remove bolt (1) and the washer (2) from the air inlet cover (3). Discard the bolt (1) and the washer (2).
Disconnect the electrical connector of the injection actuation pressure control valve (7). Remove the injection actuation pressure control valve (7) from the pump. Retain the injection actuation pressure control valve (7) for the reinstallation.

NOTE: Modifications to the tools may need to be made in order to reduce interference with engine components.

Illustration 2 (Modified 2P5494 crowfoot wrench)

Remove the hose assembly (5), the connector (8), and the elbow (6). Discard these parts.

Illustration 3

(4) HEUI pump

(5) Flexible oil line

(6) Elbow

(7) Injection actuation pressure control valve

(8) Connector

Installation of 2400716 Tube Kit

Illustration 4

(4) HEUI pump

(7) Injection actuation pressure control valve

(9) Connector

(10) Clip

(11) Washer

(12) Bolt

(13) Spacer

(14) Tube assembly

(15) O-ring

(16) O-ring

(17) Elbow

Illustration 5

(7) Injection actuation pressure control valve

(9) Connector

(15) O-ring

(16) O-ring

(17) Elbow

Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the connector (9). Install the O-ring (16) on the connector (9). Thread the connector (9) into the port on the cylinder head by hand. Tighten to 48 + 5 Nm (35 + 4 lb ft).
Apply a light coat of oil to the O-rings (15) and (16) during installation. Install the O-ring (15) on the elbow (17). Install the O-ring (16) on the elbow (17).
Back off the jam nut on the elbow (17) to the top of the threads on the elbow assembly (17). Push the washer tightly against the jam nut. Check that the washer is as tight as possible. Thread the elbow assembly (17) into the port of the HEUI pump (4). Hand tighten the elbow (17) into the port of the HEUI pump until the washer is tight against the HEUI pump (4). Unscrew the elbow assembly (17) no more than one complete turn to 40 degrees.
Align the tube assembly (14) with the connector (9) and the elbow (17). Loosely thread each end of the tube assembly (14) onto the connector (9) and the elbow (17). Position the elbow (17) in order to not create stress in the tube assembly (14).
Attach the clip (10) to the tube assembly (14). The flat side of the clip (10) must be toward the air inlet cover. Place the washer (11) onto the bolt (12). Insert the bolt (12) through the clip (10) and the spacer (13).
Insert the bolt (12) through the air inlet cover (3).
Thread the bolt (12) into the cylinder head.
Hand tighten the bolt (12).
Hand tighten both connections on the tube assembly (14).

NOTE: Ensure that there is no stress on the tube assembly (14) from any components or fittings.

Use a wrench to prevent the elbow assembly (17) from turning. Tighten the bottom tube fitting to the elbow assembly (17) to 40 + 4 Nm (29.5 + 3 lb ft).
Tighten the top tube fitting to the connector (9) to 40 + 4 Nm (29.5 + 3 lb ft).
Use a wrench to prevent the elbow assembly (17) from turning. Tighten the jam nut of the elbow assembly (17) to 24 + 2 Nm (18 + 1.5 lb ft).
Tighten the bolt (12) to 28 +/- 7 Nm (21 +/- 5 lb ft).

Illustration 6

(7) Injection actuation pressure control valve

(18) O-ring

(19) Backup ring

(20) O-ring

NOTE: Note the location of the components on the injection actuation pressure control valve prior to replacement.

Remove the existing components from the injection actuation pressure control valve (7). Discard the existing components. Install the new components for the injection actuation pressure control valve on the injection actuation pressure control valve (7). Apply a light coat of oil on the new components during installation. Install the injection actuation pressure control valve (7) into the port on the HEUI pump (4). Tighten the injection actuation pressure control valve (7) to 50 +/- 5 Nm (37 +/- 3.7 lb ft).
Reconnect the wiring to the injection actuation pressure control valve (7).
Inspect any coolant lines or any air inlet lines that were disconnected. Reinstall any coolant lines or any air inlet lines that were disconnected. If necessary, repair the lines or replace the lines.
Check all fluid levels. Fill all fluids to the proper level.
Clean up any fluids from the assembly process. Run the engine in order to check for leaks.