Information injection-pump assembly
ZEXEL
106871-5560
1068715560
NISSAN-DIESEL
1680197570
1680197570
Rating:
Service parts 106871-5560 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-97119
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.6{230}
14.
NOZZLE
Include in #1:
106871-5560
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-5560
1068715560
NISSAN-DIESEL
1680197570
1680197570
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
4.7
4.67
4.73
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
(13.4)
Vist
V
1.85
1.85
1.85
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
137
135
139
Max. variation between cylinders
%
0
-4
4
Basic
*
Injection quantity adjustment_02
Rack position
(8.4)
Vist
V
2.6
2.5
2.7
Pump speed
r/min
335
335
335
Average injection quantity
mm3/st.
14
12
16
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.
----------
----------
----------
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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.
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
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