Information injection-pump assembly
BOSCH
9 400 610 428
9400610428
ZEXEL
101401-9490
1014019490
NISSAN-DIESEL
1670017D01
1670017d01
Rating:
Service parts 101401-9490 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-17D02
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 428
9400610428
ZEXEL
101401-9490
1014019490
NISSAN-DIESEL
1670017D01
1670017d01
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
3.2
3.15
3.25
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
13.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
92
90.4
93.6
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
9.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
13
11.2
14.8
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(13.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
92
91
93
Basic
*
Fixing the lever
*
Boost pressure
kPa
97.3
97.3
Boost pressure
mmHg
730
730
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.05
Pump speed
r/min
1550
1550
1550
Average injection quantity
mm3/st.
113.5
109.5
117.5
Fixing the lever
*
Boost pressure
kPa
97.3
97.3
Boost pressure
mmHg
730
730
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-1
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
55.5
51.5
59.5
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
R2-1
Boost pressure
kPa
13.3
12
14.6
Boost pressure
mmHg
100
90
110
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2(R1-0.
35)
Boost pressure
kPa
84
84
84
Boost pressure
mmHg
630
630
630
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.
5.5
5.2
5.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerances for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=L12 BCL=1+-0.1mm
----------
----------
T1=L12 BCL=1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
(2)Use the hole at R = aa
----------
aa=32mm
----------
a=71deg+-5deg b=41deg+-3deg
----------
aa=32mm
----------
a=71deg+-5deg b=41deg+-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=4+-0.2V Vc=0.58+-0.3V
----------
V1=5+-0.02V
----------
V1=5+-0.02V Va=(5)V Vb=4+-0.2V Vc=0.58+-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=5deg
----------
a=(50deg)
----------
aa=5deg
----------
a=(50deg)
Information:
This Revised Service Letter replaces the 30May2018 Service Letter. Changes have been made to the Parts Needed.
TERMINATION DATE
31May2020
PROBLEM
The DEF injector can become plugged on certain 953K and 963K Track-Type Loaders. If the DEF injector becomes plugged it can lead to partial or full blockage of DEF flow.
AFFECTED PRODUCT
Model Identification Number
953K LJT00100-00211
963K LBL00100-00678
PARTS NEEDED
Qty
Part Number Description
1 4182073 GASKET AS
1 4609257 INJECTOR AS-DEF
1 5457669 SFWR GP-A1000
1 5460139 SFWR GP-A1000
1 BULK_COOLANT COOLANT See OMM
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 6% 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
DEF Injector Replacement ? Remove and Install:
Remove DEF injector and replace. Follow Disassembly and Assembly, UENR0006, for DEF Injector and Mounting - Remove and Install.
Update Engine Software:
Reflash the engine controller (ECM) with the software listed in the Parts Needed or latest available on SIS Web.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-5000 hrs,
37-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 100.0%
This is a 1.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.