PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED HEUI INJECTORS ON CERTAIN 3412E POWERED 773D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED HEUI INJECTORS ON CERTAIN 3412E POWERED 773D OFF-HIGHWAY TRUCKS

Usage:

SEBE8279-01

January 28, 2003
(Revised May 2003)
D-28

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED HEUI INJECTORS ON CERTAIN 3412E POWERED 773D OFF-HIGHWAY TRUCKS
1290		PS50599

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 "PS50599" 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.

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 administered unless the customer is using a 2 micron secondary fuel filter and using either the preferred CH-4, CG-4, or CF-4 Oil.

NOTE: This Revised Service Letter replaces the January 28, 2003 Service Letter. Changes have been made to the Mail Codes, and the Parts Needed.

TERMINATION DATE

January 31, 2005

PROBLEM

Replace failed HEUI injectors on certain 3412E powered 773D Off-Highway Trucks. On certain machines, the 1388754,1388756, 1590835, 1590836, 1747526/">1747526, 1747527 or earlier Injectors may experience a failure. This can be caused either by:

An individual injector failure, which can be repaired by replacing only the failed injector.

Excessive injector poppet valve oil leakage on multiple fuel injectors, which can be repaired by replacing a complete set of injectors and software (and possible FLS/FTS reset).

AFFECTED PRODUCT

Use the Machine S/N Range for the affected injector build period in this service program as shown in the table below.

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Model	Identification Number	Engine S/N Range
773D	7FZ73-227 BGL73-111	IDX1-211 IDX154-211

PARTS NEEDED

A conversion involves the replacement of the full set of injector and a software update. Individual injectors may still be replaced. The troubleshooting tests (see attached rework procedure) should be used in order to determine the repair method. NOTE: Do not mix the injector part numbers from Table 1 with those found in Table 2.

NOTE: Verify that the software listed in Table 2 is available before you start to convert the fuel system. The latest software will be available through the Caterpillar Service Information System.

For replacement of individual failed injectors including 1388754, 1388756, 1590835, 1590836, 1747526/">1747526, 1747527 or earlier injectors, use the following parts:

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Table 1 ? Replacement of individual injectors
Qty	Part Number	Description
1	1747526	INJECTOR GP
2	1167221	SEAL
1	1167222	SEAL
1	9X7681	SEAL
1	3E6747	SEAL

For replacement of complete set of failed injectors-

The parts required for complete update is noted in the list below.

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Table 2 ? Conversion of full sets
Qty	Part Number	Description
1 per cylinder	1984752	INJECTOR GP
1	2143347	SOFTWARE
2 per cylinder	1167221	SEAL
1 per cylinder	1167222	SEAL
1 per cylinder	9X7681	SEAL
1 per cylinder	3E6747	SEAL

*NOTE: Old interlock code = 12, new interlock code = 114. Old software part number = 1775372.

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

If individual injectors are replaced on 3412E machines:

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-4000 0-48 mos	100%	2	0	0	0	0
4001-8000 0-48 mos	33.3%	1	0	0	50%	1
NOTE: This is a 2?hr job and is applicable for up to 2 injector replacements. When more than 2 injectors are required, please refer to service claim allowance for Complete Injector Sets.

If complete injector sets are replaced on 3412E machines:

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-4000 0-48 mos	100%	7	0	0	0	0
4001-8000 0-48 mos	33.3%	3.5	0	0	50%	3.5
NOTE: This is a 7-hour job. Actual hours permitted up to maximums noted above.

PARTS DISPOSITION

NACD Dealers, return Injector(s) to: Caterpillar Inc.

Attn: Fergal O?Shea ? PS50599
Service Claims Room
8201 N. University
Peoria, IL 61615

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

Attach. (1-Rework Procedure)

Rework Procedure

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

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

Test for Cylinder Cutout:

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

NOTE: If this is the third injector failure, related to this Service Letter, and to the same engine serial number within 120 calendar days, replace all the injectors.

NOTE: It is also possible that multiple injectors are functioning improperly. Complete "Test for Leakage from Poppet Valve" in order to evaluate potential excessive injector leakage and need for fuel system conversion.

Test for Leakage from Poppet Valve:

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

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

Restart the engine and run at low idle with no load.
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.
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.
If multiple injectors are discovered with excessive leakage from the poppet valve, update the full set of injectors and software. 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.

NOTE: Special tooling is required to clean the carbon out of the injector sleeves before reassembly. Do not reuse the grommets on top of the injector. The proper torque sequence for the fuel injector installation is extremely important in order to achieve satisfactory injector life. Failure to follow the Special Instruction REHS0116 "Check List" may cause 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.