Information injection-pump assembly
ZEXEL
106871-5540
1068715540
NISSAN-DIESEL
1680197573
1680197573
Rating:
Cross reference number
ZEXEL
106871-5540
1068715540
NISSAN-DIESEL
1680197573
1680197573
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0120
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-7-5-
4-3-6-2
Pre-stroke
mm
3.9
3.87
3.93
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-5 deg. 135 134.75 135.25
Cal 1-5 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-3 deg. 225 224.75 225.25
Cal 1-3 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Rack position
(13.7)
Vist
V
1.8
1.8
1.8
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
141.5
139.5
143.5
Max. variation between cylinders
%
0
-4
4
Basic
*
Injection quantity adjustment_02
Rack position
(9)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
330
330
330
Average injection quantity
mm3/st.
16
14
18
Max. variation between cylinders
%
0
-10
10
Test data Ex:
Governor adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N4=800r/min C4=(9deg) t1=1.7--sec. t2=1.7--sec.
----------
N1=400r/min N2=1000++r/min N3=- C1=9+-0.3deg C2=3.5++deg C3=- P1=0kPa(0kgf/cm2) P2=294kPa(3kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
----------
L=1-0.2mm N4=800r/min C4=(9deg) t1=1.7--sec. t2=1.7--sec.
----------
N1=400r/min N2=1000++r/min N3=- C1=9+-0.3deg C2=3.5++deg C3=- P1=0kPa(0kgf/cm2) P2=294kPa(3kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder.
(3)-
(4)-
----------
----------
a=(90deg)
----------
----------
a=(90deg)
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 19 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------
----------
----------
----------
Information:
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.
Termination Date
July 31, 1996Problem
0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 need to be removed from Parts Stock.Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 01, 1995 at plant number 068).
Action Required Cont.
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
TEPS/MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 removed from Parts Stock.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".
Termination Date
July 31, 1996Problem
0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 need to be removed from Parts Stock.Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 01, 1995 at plant number 068).
Action Required Cont.
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
TEPS/MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 removed from Parts Stock.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".