101609-3830 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093830

This Program must be administered assoon as possible. When reporting the repair, use "PI30156" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI30156" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe March 24, 2001 Service Letter. Changes were made to Parts Needed, ReworkProcedure, Service Claim Allowances, Owner Notification and Parts Disposition. This Service Letter should not be performedon engines with greater than 7500 miles (>12000 KM) or >150 hours.
COMPLETION DATE
TERMINATION DATE
September 30, 2001 March 31, 2002PROBLEM
Due to a manufacturing error, there is a possibilitythat numerous 1043568 Injector Pushrods missed the heat treating operation.Certain C-10, C-12, 3176C, and 3196 engines will need to have the injectorpushrods checked and possibly replaced. This Service letter should onlybe performed on engines with between 0 to 7500 miles (0 to 12000 kM) or0-150 hours.AFFECTED PRODUCT
Model Identification NumberTRUCK/COMMERCIAL ENGINESC-10 3CS18811 ? 193268YS7628 - 7646C-12 2KS61890 ? 632739SM277 - 3363176C IND 2AW1272 ? 13063196 IND 1DW611 ? 6143176C MAR 6BW498 ? 4993196 MAR 2XR3757 ? 38623176C Machine 3PD168 - 2023196 Machine 5ED216 - 2373176C Machine 7ZR5409 - 55163196 Machine 6AR2595 - 2635MACHINES725 AFX130-131, 142-145, 148-150,174, 177-179730 AGF217-218, 225-228345 AGS480, 562, 564, 566, 571,575, 578, 582-584ALB197APB110-112CFM27665E 6GS632, 634, 637, 639?649, 65275E 1HM310-3126HS647, 64985E 1NM230-2316JS668-669, 67295E 1SM282 ? 2896KS985, 987, 993PARTS NEEDED
AS REQUIRED
1043568 Injector Pushrods(depending on the results of the inspection,0?6 pushrods may be needed for the rework? Only individual pushrods foundto be soft need to be replaced)AS REQUIRED
Injector Group(depending on the results of the pushrodinspection , 0-6 injectors may be needed for the rework? An injector shouldbe replaced only if the pushrod for that particular injector isfound to be soft and if the engine has more than 200 MILES (322KM) or 20 HOURS.)ACTION REQUIRED
Remove the valve covers.
Using a medium to coarse flat file against thecup of the pushrod, stroke the file.
If the push rod is soft you will feel a distinctdrag as the file digs into the material.
If the push rod is hard the file will feel likeit is passing over glass as the file slides across the hard surface.
If you are not certain if a pushrod is soft orhard CALL YOUR TC OR THE CAT PRODUCT ANALYST AT:(800)447-4986.
If a pushrod is soft, remove the rocker arm andreplace the pushrod. Tighten the rocker stand bolts according to the torquevalue found in Service Manual.
IF A PUSHROD IS FOUND TO BE SOFT AND THE ENGINEHAS MORE THAN 200 miles (322 KM) OR 20 hours on it replace onlythe injector that is driven by the soft pushrod. Lubricate the two largero-ring seals with engine oil and install the injectors. Tighten the injectorhold down