Caterpillar Help

Keith Browning · August 21, 2008

I hope one of the CAT guys can help me here, I am on SIS WEB attempting to look up parts for the first time and having trouble finding what I need. I can find the return tube but not the pressure line and fitting... The graphics I come up with show a tube, not a hose.

It's a 2001 F650 with a 3126B engine:

I need the high pressure oil line from the HPOP to the cylinder head and the fitting at the pump. This is the 8" rubber line with the quick connect ends.

Arrangement #8YL
.
Serial #0083806H

HeuiTim · August 21, 2008

When in sis looking at PUMP & MTG GP-UNIT INJ HYD, click on truck engine news, you will see updated parts. Special instruction will show instructions for this or use the media number in media search. Should be able to buy the group 240-0717.

A Special Instruction, REHS2060 , "Installation Instructions for the 240-0717 Engine Oil Lines Gp for the Hydraulic Electronic Unit Injector (HEUI) Pump" is Available {1307, 1714}

SMCS - 1307; 1714

Truck Engines:

3126B (S/N: BKD1-UP; 1AJ1-UP; 5GL1-UP; 8YL1-UP; 7AS1-UP; 8SZ1-UP)

3126E (S/N: DPF1-UP; 6ZG1-UP; CKM1-UP; CRP1-UP; 9SZ1-UP)

The special instruction contains information for installing the 240-0717 Engine Oil Lines Gp. The 240-0717 Engine Oil Lines Gp is available for repair of the high pressure oil line on the Hydraulic Electronic Unit Injector Pump. The kit is used in order to replace the flexible high pressure oil line with a more durable steel line.

The 240-0717 Engine Oil Lines Gp is adaptable to the engines that are listed above.

The Special Instruction is available through the normal literature distribution system. The publication can also be found on the Caterpillar Service Information System (SIS).

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Thu Aug 21 09:33:06 EDT 2008

Keith if line is leaking or loose at fitting on pump, replace pump. Once that fitting starts to leak it will come back, the pump thread will feel ok and tighten up, not leak when you have it but will eventually blow off on the customer. If the pump fitting is not leaking or loose you will be all set, just follow the instructions and replace all parts in instructions.

Tim

HeuiTim · August 21, 2008

Special Instruction

Installation Instructions for the 240-0717 Engine Oil Lines Gp for the Hydraulic Electronic Unit Injector (HEUI) Pump{1307} Media Number -REHS2060-00 Publication Date -01/01/2004 Date Updated -07/01/2004

i02021916

Installation Instructions for the 240-0717 Engine Oil Lines Gp for the Hydraulic Electronic Unit Injector (HEUI) Pump{1307}

SMCS - 1307

Truck Engines:

3126B (S/N: BKD1-UP; 1AJ1-UP; 5GL1-UP; 8YL1-UP; 7AS1-UP; 8SZ1-UP)

3126E (S/N: DPF1-UP; 6ZG1-UP; CKM1-UP; CRP1-UP; 9SZ1-UP)

Introduction

The 240-0717 Engine Oil Lines Gp is available for repair of the high pressure oil line. The kit is used in order to replace the flexible high pressure oil line. The oil line is part of the Hydraulic Electronic Unit Injector Pump.

Note: This kit includes two different spacers. 122-5855 Spacer has an outer diameter of 20 mm (0.79 inch) and a length of 26 mm (1.02 inch). 135-5096 Spacer has an outer diameter of 17 mm (0.67 inch) and a length of 16 mm (0.63 inch). Make sure that the correct spacer is used. Failure to use the correct mounting hardware and the correct installation procedure may result in failure of the Engine Oil Lines Gp.

The 240-0717 Engine Oil Lines Gp is used on engine models with the following serial number prefixes (S/N: 1AJ; 5GL; 6ZG; 7AS; 8YL; 8SZ; 9SZ; BKD; CKM; CRP; DPF).

Table 1 Components in 240-0717 Engine Oil Lines Gp

Callout Part Number Description Quantity

11 9M-1974 Washer 1

13 122-5855 Spacer 1

13 135-5096 Spacer 1

10 8S-8820 Clip 1

12 8C-5748 Bolt 1

9 6V-8636 Connector 1

17 6V-9001 Elbow 1

15 214-7568 O-ring 2

16 221-3494 O-ring 2

14 241-3782 Tube assembly 1

18 033-6028 O-ring 1

19 123-3132 Backup ring 1

20 033-6039 O-ring 1

Note: Engines that are equipped with a remotely mounted fuel filter base must use 122-5855 Spacer . A remotely mounted fuel filter base allows the oil lines and the spacer to be directly bolted to the inlet manifold cover. Refer to illustration 2. Discard the 135-5096 Spacer .

Note: Engines that use the middle mounted fuel filter bracket must use 135-5096 Spacer for the installation of the kit. Refer to illustration 1. Discard the 122-5855 Spacer .

Removal of the Flexible Oil Line

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NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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NOTICE

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.

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

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Illustration 1 g01043884

Air inlet cover with the middle mounted fuel filter bracket

(1) Bolt

(2) Washer

(3) Air inlet cover

(4) 163-8702 Bracket for mounting the fuel filter

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Illustration 2 g01043885

The air inlet cover without the fuel filter mounting bracket is found on engines that have a remotely mounted fuel filter base.

(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 (8). Remove the injection actuation pressure control valve (8) from the pump. Retain the injection actuation pressure control valve (8) for the reinstallation.

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

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Illustration 3 g01007381

Modified 2P-5494 crowfoot wrench

Remove the hose assembly (6) and the two connectors (7). Discard these parts.

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Illustration 4 g01043882

(5) HEUI pump

(6) Flexible oil line

(7) Connector

(8) Injection actuation pressure control valve

Installation of the 240-0717 Engine Oil Lines Gp

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Illustration 5 g01043862

(5) HEUI pump

(8) 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

Note: Some engines may not have a fuel filter mounting bracket. The existence of the fuel filter mounting bracket on the air inlet cover helps to determine the proper spacer to use. If the fuel filter bracket is mounted on the air inlet cover then the 135-5096 Spacer must be used. If the fuel filter bracket is not mounted on the air inlet cover then the 122-5855 Spacer must be used.

Note: In order to determine the correct spacer for installation, refer to the original assembly. Refer to illustration 1 and illustration 2. Refer to illustration 6 and illustration 7 for the correct installation of the spacer and clip.

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Illustration 6 g01043888

Correct installation of 122-5855 Spacer with no fuel filter mounting bracket

(10) Clip

(11) Washer

(12) Bolt

(13) Spacer

(14) Tube assembly

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Illustration 7 g01045006

Correct installation of 135-5096 Spacer with the fuel filter mounting bracket

(10) Clip

(11) Washer

(12) Bolt

(13) Spacer

(14) Tube assembly

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Illustration 8 g01043711

(8) 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 N·m (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 (5). Hand tighten the elbow (17) into the port of the HEUI pump until the washer is tight against the HEUI pump (5). 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) .

Note: This kit includes two different spacers. 122-5855 Spacer has an outer diameter of 20 mm (0.79 inch) and a length of 26 mm (1.02 inch). 135-5096 Spacer has an outer diameter of 17 mm (0.67 inch) and a length of 16 mm (0.63 inch). Make sure that the correct spacer is used. Failure to use the correct mounting hardware and the correct installation procedure may result in failure of the Engine Oil Lines Gp.

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 N·m (29.5 + 3 lb ft).

Use a wrench in order to prevent the connector (9) from turning. Tighten the top tube fitting to the connector (9) to 40 + 4 N·m (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 the HEUI pump to 24 + 2 N·m (18 + 1.5 lb ft).

Tighten the bolt (12) to 28 ± 7 N·m (21 ± 5 lb ft).

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Illustration 9 g01043714

(8) 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 (8). Discard the existing components. Install the new components for the injection actuation pressure control valve on the injection actuation pressure control valve (8). Apply a light coat of oil on the new components during installation. Install the injection actuation pressure control valve (8) into the port on the HEUI pump (5). Tighten the injection actuation pressure control valve (8) to 50 ± 5 N·m (37 ± 3.7 lb ft).

Reconnect the wiring to the injection actuation pressure control valve (8) .

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. Repair any fittings that may be leaking.

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Thu Aug 21 09:37:38 EDT 2008

Keith Browning · August 21, 2008

Thanks Tim! The fitting on the pump is not loose as far as it's relationship with the pump itself. My impression is that the hose feels a bit looser on the fitting than I would like. If I am going to be upgrading this to a steel tube then the fitting is going to be replaced anyway. Good advice though! We have had problems with those fittings loosening and blowing out the o-rings on the pumps on 7.3L engines. The fix was new o-rings and Loc-Tite on the threads.

What would be a fair labor time for this repair?

HeuiTim · August 22, 2008

What would be a fair labor time for this repair?

I checked time requirement guide, heui tubes, 1-1.4hr. So I would say 1-2 hours but if it is not warranty, you could fairly charge for diag and installing an update that eliiminates problem, taking care of customer. 3 hours???

Keith Browning · August 22, 2008

I went with 2.5 - includes diag, time to look up the parts and I will wash the engine when done. I was able to get the kit yesterday as CAT had it in stock. Looks straight forward and aside from that the customer wants a few service items taken care of so its all good.

LARRY BRUDZYNSKI · August 22, 2008

Keith, I don't know how many 3126's you see come thru the door but it might be a good idea to put one of those kits as well as the oil cooler gasket kit #142-2222 in stock. Pretty common on the 3126's

Keith Browning · August 22, 2008

Larry, for us it makes no sense to stock any CAT parts beyond filters. We are a TEPS dealer with no authority to perform any real repairs to these engines. I have enough information and diagnostic equipment to determine whether a concern is a Ford problem or a Caterpillar problem and decide who gets to perform the repair. Sure, we can do some small repairs and we are free to perform out of warranty repairs, but since we have no special tools, only see a handful of concerns per year it makes no sense to stock anything - especially with the current economic conditions. Whats more is that it would cost too much to become a certified CAT service dealer and with CAT dropping out of the on-highway engine business in two model years it's pointless.