101601-0780 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016010780 5156003702

Product smu Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-4000 100% 7.0 0 0 0 0
4001-8000 50% 3.5 0 0 50% 0
This is a 7.0?hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.Test 1: Use "Test for CylinderCutout" to determine if individual injector replacements (using originalinjector part) are needed.Test 2: Use "Test for Leakagefrom Poppet Valve" to determine if full injector sets (using new injectorparts and a software change from the table) 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 +/- 125rpm. An extremely rough running engine will need to be diagnosed by othermethods.
Cut out one bank of cylinders.
Engine rpm and the fuel positionon the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from Poppet Valve:
Warm engine out of Cold Mode to normaloperating temperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
!Personal injury can result from hot oil and components. Do not allowhot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port are an indication ofexcessive poppet valve leakage.
If multiple injectors are discovered with excessiveleakage from the poppet valve, update the full set of injectors and softwarewith the new version given in this Service Letter. Install new seals forthe injector and the jumper tube during this repair. The injector repairprocedure can be found in Special Instruction REHS0116. The old softwarepart number should be documented for potential future reference.
Before proceeding with updating