2002/08/26 Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors {1290} Caterpillar

Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors {1290}

2002/08/26 [SEPD0644]

2002/08/26 New Linkage Components Improve the Operation of the Winch {5161}

2002/08/26 A New Location of the Vent for the Rear Axle Prevents Loss of Oil {3260, 3260}

FUEL SYSTEM

PUMP GP-FUEL INJECTION

2002/08/26 Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors {1290}

Cold Planer:
PM-565 CP TT (S/N: 3TK113-123)
PM-565B (S/N: 8GS1-226)
Earthmoving Compactor:
836 (S/N: 7FR1-478)
Excavator:
5110B (S/N: AAA1-329)
Motor Grader:
24H (S/N: 7KK1-220)
Off-Highway Truck/Tractor:
769D (S/N: BBB1-136; 5SS1-652; 5TR1-1054)
771D (S/N: BCA1-135; 6JR1-309; 6YS1-441)
773D (S/N: 7CS1-1005; 7ER1-971)
773E (S/N: BDA1-UP)
775D (S/N: 8AS1-631; 6KR1-380)
775E (S/N: BEC1-UP)
Track-Type Tractor:
D9R (S/N: 8BL830-1514; ACL1-853)
D9R DS PS (S/N: ABK1-708; 7TL557-1409)
D10R (S/N: 3KR1-1731; AKT1-UP)
Wheel Loader:
988F Series II (S/N: 2ZR1-2466)
990 Series II (S/N: BCR1-UP; 4FR1-641)
Wheel Tractor:
834B (S/N: 7BR1-737)
844 (S/N: BBN1-UP; 2KZ1-409)
Wheel Tractor-Scraper:
631E (S/N: 1AB1640-2111)
631E Series II (S/N: 1NB1390-1498)
631G (S/N: AWK1-272)
633E Series II (S/N: 2PS290-319)
637E (S/N: 1FB660-1001)
637G (S/N: AXT1-316)
651E (S/N: 4YR1-402)
657E (S/N: 7KR1-329; 6PR1-114; 6TR1-407; 5YR1-519)

Reference: Special Instruction, REHS1385, "Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors"

Description of Change: The 3408E machine engines and the 3412E machine engines have new fuel injectors. The improved fuel injectors offer increased reliability and durability. Refer to Special Instruction, REHS1385, "Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors" for the instructions on the following situations:

Starting and power complaints
False engine start
Hard cold starts

Note: Do not mix original injectors and injectors with new part numbers. An update includes the replacement of the entire set of injectors with new part numbers. The flash files must also be updated.

Adaptable To: The Engine Serial Numbers that are effective with the new injectors and flash files are listed in Table 1. The approximate Machine Serial Numbers for the machines are also included. The Engine Serial Numbers that are adaptable to the new injectors and new flash files are found in Table 2.

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Table 1
Machine Model	Machine Serial Number	Engine Serial Number
3412E Tier 1 Engine
775E	S/N:BEC	S/N:80M
3412E Tier 2 Engine
844	S/N:BBN	S/N:5JJ
990	S/N:BCR	S/N:5JJ
773E	S/N:BDA	S/N:5JJ
D10R	S/N:AKT	S/N:5JJ
D10R (EEC Sound Package)	S/N:AKT	S/N:5JJ

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Table 2
Machine Model	Machine Serial Number	Engine Serial Number
3408E Tier 1 Engine
834B	S/N:7BR1-737	S/N:99C1-7377
834B (Spain only)	S/N:7BR1-737	S/N:99C1-7377
836	S/N:7FR1-478	S/N:99C1-7377
836	S/N:7FR1-478	S/N:99C1-7377
988F	S/N:2ZR1-2466	S/N:99C1-7319


631E	S/N:1AB1640-2111	S/N:99C1-7369
631E	S/N:1NB1390-1498	S/N:99C1-7369
633E	S/N:2PS290-319	S/N:99C1-7371
637E	S/N:1FB660-1001	S/N:99C1-7371
657E (Single Hp)	S/N:7KR1-250	S/N:99C1-3087
657E (Single Hp)	S/N:6PR1-103	S/N:99C1-3087
657E(Dual Hp)	S/N:7KR251-329	S/N:99C1-7370
657E(Dual Hp)	S/N:6PR104-114	S/N:99C1-7370
769D (France only)	S/N:5TR1-1054	S/N:99C1-7380
769D	S/N:5TR1-1054	S/N:99C1-7380
769D	S/N:5SS1-652	S/N:99C1-7380
771D (France only)	S/N:6JR1-309	S/N:99C1-7380
771D	S/N:6JR1-309	S/N:99C1-7380
771D	S/N:6YS1-441	S/N:99C1-7380
D9R	S/N:8BL830-1514	S/N:99C1-7375
D9R	S/N:7TL557-1409	S/N:99C1-7375
PM-565	S/N:3TK113-123	S/N:99C1-2500
PM-565B	S/N:8GS1-226	S/N:99C1-7470
3408E Tier 2 Engine
631G	S/N:AWK1-272	S/N:5XD1-843
637G	S/N:AXT1-316	S/N:5XD1-843
769D	S/N:BBB1-136	S/N:5XD1-837
771D	S/N:BCA1-135	S/N:5XD1-837
D9R	S/N:ABK1-708	S/N:5XD1-843
D9R	S/N:ACL1-853	S/N:5XD1-843
3412E Tier 1 Engine
844	S/N:2KZ1-409	S/N:80M1-5177
990	S/N:4FR1-641	S/N:80M1-5177
24H	S/N:7KK1-220 ⁽¹⁾	S/N:80M1-5199
651E (Single Hp)	S/N:4YR1-203	S/N:80M1-1895
651E (Dual Hp)	S/N:4YR204-402	S/N:80M1-5176
657E (Single Hp)	S/N:5YR1-257	S/N:90M1-1899
657E (Single Hp)	S/N:6TR1-207	S/N:90M1-1899
657E (Dual Hp)	S/N:5YR258-519	S/N:80M1-5176
657E (Dual Hp)	S/N:6TR208-407	S/N:80M1-5176
773D (France only)	S/N:7ER1-971	S/N:80M1-5189
773D	S/N:7ER1-971	S/N:80M1-5189
773D	S/N:7CS1-1005	S/N:80M1-5189
775D	S/N:8AS1-631	S/N:80M1-5189
775D	S/N:6KR1-380	S/N:80M1-5189
D10R	S/N:3KR1-1731	S/N:80M1-4649
D10R (EEC Sound Package)	S/N:3KR1-1731	S/N:80M1-4649
5110B	S/N:AAA1-329	S/N:80M1-5101

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Complete Serial Number range has not been defined.

Troubleshooting Procedure for Hydraulic Electronic Unit Injectors

Refer to Special Instruction, REHS1385, "Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors" for the proper troubleshooting procedure. The Special Instruction can identify the repair method from the results of two tests.

Test for Cylinder Cutout

Use the Special Instruction, REHS1385, "Test for Cylinder Cutout" in order to determine if the replacement of individual injectors is required. An original injector may be used in order to replace a suspect injector from this test.

Test for Leakage from Poppet Valve

Use Special Instruction, REHS1385, "Test for Leakage from Poppet Valve" in order to determine if an upgrade of the fuel system is needed. An upgrade consists of the replacement of an entire set of injectors. New software is also required during an upgrade.