Information injection-pump assembly
BOSCH
9 400 610 427
9400610427
ZEXEL
101401-9460
1014019460
NISSAN-DIESEL
1670017D00
1670017d00
Rating:
Service parts 101401-9460 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-17D01
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 427
9400610427
ZEXEL
101401-9460
1014019460
NISSAN-DIESEL
1670017D00
1670017d00
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-4120
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
1-3-4-2
Pre-stroke
mm
4
3.95
4.05
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
83.5
81.9
85.1
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
12
10.2
13.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.8)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
83.5
82.5
84.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
71.3
71.3
Boost pressure
mmHg
535
535
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.05
Pump speed
r/min
1550
1550
1550
Average injection quantity
mm3/st.
106
102
110
Fixing the lever
*
Boost pressure
kPa
71.3
71.3
Boost pressure
mmHg
535
535
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-0.8
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
45.2
41.2
49.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R2-0.8
Boost pressure
kPa
18.7
17.4
20
Boost pressure
mmHg
140
130
150
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2(R1-0.
25)
Boost pressure
kPa
58
58
58
Boost pressure
mmHg
435
435
435
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
5
4.7
5.3
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=K81 BCL=0.8+-0.1mm
----------
----------
T1=K81 BCL=0.8+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=70deg+-5deg b=(40deg)+-3deg
----------
aa=32mm
----------
a=70deg+-5deg b=(40deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg
0000001501 POTENTIO METER
(A) : Governor plan view
(B): Potentiometer harness terminal
(C): Potentiometer connection diagram
(D) : Output voltage standard value
(S): Voltage
P/M: potentiometer
(v): output voltage (V)
(p): direction of potentiometer rotation
1. Adjustment procedures
(1)Apply DCV1 to potentiometer harness terminal (B) to obtain the specified output voltage.
(2)Fix the speed lever at the full side.
(3)Loosen the bolt (S), and move the potentiometer from left and right.
(4)Adjust so that the output voltage at full is within the standard values.
(5)Fix bolt (S).
(6)Repeatedly move the speed lever from the full side to the idle side.
(7)Check that it is within the standard values at full and idle.
----------
V1=5+-0.02V
----------
V1=5+-0.02V Va=(5)V Vb=(3.83)+-0.2V Vc=0.5+-0.3V
----------
V1=5+-0.02V
----------
V1=5+-0.02V Va=(5)V Vb=(3.83)+-0.2V Vc=0.5+-0.3V
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole (position of gear's distinguishing mark) at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=8deg
----------
a=(50deg)
----------
aa=8deg
----------
a=(50deg)
Information:
TERMINATION DATE
30Apr2020
PROBLEM
The existing injector nozzles can leak Diesel on certain D8R Track-Type Tractors. If the existing injector nozzles leak it can cause dilution of the engine oil and affect engine performance.
AFFECTED PRODUCT
Model Identification Number
D8R 9EM07939, 8637, 8698, 9196, 9198-9199, 9202, 9207, 9321, 9323, 9325-9327, 9334-9339, 9364-9365, 9368-9372, 9376, 9380-9381, 9387-9397, 9415-9417
RJM00124, 126-127, 255, 257-271, 274-281, 284, 307-312, 340, 364, 372-381, 385-388, 395, 405-407, 409-414, 422-447, 453, 461-464, 470-479, 487, 489-490, 496-497, 504, 508-509, 558, 560, 563-564
T5X00469
PARTS NEEDED
Qty
Part Number Description
1 1R0716 FILTER AS-LUBE (After Failure Only)
2 5P5678 SEAL
6 7W2315 RETAINER
6 1291351 NOZZLE AS-DI F V
6 2033940 SEAL-O-RING
6 4640509 SEAL-O-RING
1 OIL_BULK 15W40 Cat DEO 42 L (After Failure Only as Req)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 13% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Replace the injector nozzles.
For the repair of the Affected Product, ensure the injector nozzles have a date code of "CAT 01 A 17" (1st Jan 2017) or a later date. See Image 1 with date code details (example date 7th Dec 2016). Image 2 shows the general ID location on an injector nozzle.
Refer to Disassembly and Assembly, SENR1029 for removing and installing the valve covers, valve cover bases, and replacing injectors.
For an injector nozzle replacement, after failure, when a leak has occurred, replace the engine oil and filter.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job
An additional 1 hour is allowed for after failure (to replace oil and filter)
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.