107691-2340 ZEXEL INJECTION-PUMP ASSEMBLY Cross 1076912340

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.
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 "PS5331" 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.
Termination Date
October 31, 1998Problem
Some 3116 and 3126 HEUI Engines may have excessive oil consumption as a result of oil leaking past the intensifier piston o-ring inside the injector. Engine oil consumption becomes excessive and may increase rapidly. There are no traditional signs of oil consumption, smoke, blow-by, etc. The engine has no performance problem, has good power and normal exhaust smoke.
The problem seems to be very low frequency and is not batch related.
Affected Product
Model & Identification Number
3116 (8WL1-Up)
3126 (1WM1-Up 4ES1-Up )
Parts Needed
3116 Engines6 - 1162784 Injectors (for 170 Hp)6 - 1166706 Injectors (for 185, 195, 215, 230, 250 and 275 Hp) 3126 Engines6 - 0R4970 Injectors (for 230, 250, 275, 300 and 330 Hp)6 - 0R4972 Injectors (for 175, 190 and 210 Hp)Action Required
See the attached rework procedure.
Service Claim Allowances
Labor Hour Breakdown TK = TopKickMC = Medium Hood ConventionalClaim 1290-500 for an additional 1.6 hours if the repair is made in a motor home chassis, cab type (RV), or bus chassis, cab type (BU).
Parts Disposition
TEPS/MEPS Dealers must return the affected part(s) to their Caterpillar dealer.
Parts must be returned undamaged in the original shipping boxes to:
Caterpillar Inc.
Attn: Michael Mosley - PS5331
8401 N. University
Peoria, Illinois 61615
Injectors must be sealed in a plastic bag to prevent fuel from leaking out during shipment.
A clear, legible copy of the service report in a plastic page protector must be included in the box with the returned injectors. The report must be packaged to arrive free of oil, grease and diesel fuel.
Attach.(1 - Rework Procedure)Rework Procedure
Check to see if PS8826 (Jumper-tube Rework) is to be applied to the affected engine. Perform PS8826 if it has not been performed prior to oil consumption test.
Document the oil consumption for 30 days using the attached Oil Consumption Test Sheet, Form Number 01-081227.
All of the following steps must be followed in order to establish base line data for oil consumption for full warranty reimbursement.
1. Change oil and filter at the beginning of the test to establish base line at normal change interval. Use CG-4 oil and new oil filter. Oil and filter are not claimable under this letter.
2. Refill with the proper amount of oil; 27liters/29 quarts, and 18 liters/19 quarts per the July 1997 Operations Maintenance Manual.3. Inspect for external leaks around the gaskets and the front and rear main seals.4. Inspect the air compressor air tanks for excess oil.5. Inspect the turbo oil drain line for excessive oil indicating seal leak.6. At the completion of