Information injection-pump assembly
BOSCH
9 400 610 429
9400610429
ZEXEL
101401-9500
1014019500
NISSAN-DIESEL
1670017D71
1670017d71
Rating:
Service parts 101401-9500 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
9 400 610 429
9400610429
ZEXEL
101401-9500
1014019500
NISSAN-DIESEL
1670017D71
1670017d71
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)Tolerance 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)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
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 LEVER
(A) Speed lever (lower)
(B) Stopper bolt
(C) Special lever (upper)
a:Point A (inside lever)
1. Special lever adjustment
(1)With the speed lever at the idle position, set the accelerator lever stopper bolt so that the accelerator lever contacts the speed lever at point a.
(2)Back off the stopper bolt L and set.
----------
L=1+0.5mm
----------
----------
L=1+0.5mm
----------
0000001601 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:
PROBLEM
The existing diesel exhaust fluid manifold can fail on certain 2570D, 2670D, 563D, and 573D Wheel Feller Bunchers, and 525D, 535D, 545D, and 555D Wheel Skidders. If the existing DEF manifold fails it can lead to inducements and eventual engine shutdown.
AFFECTED PRODUCT
Model Identification Number
2570D D2500112-00114
2670D D2600208-00211
525D GKP00477-00524, 527
535D MTP00386-00448, 450-453
545D KGP00254-00284, 287
555D PGY00153-00159
563D D6300115-00146
573D D7300209-00226
PARTS NEEDED
Qty
Part Number Description
1 3915262 GASKET
1 5280527 MANIFOLD GP
1 DCUSOFTWARE DCU SOFTWARE
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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
Update the Engine and DCU software files to the latest available in SIS Web. Replace the existing diesel exhaust fluid manifold with the 528-0527 diesel exhaust fluid manifold. Use a new 391-5262 gasket when installing a new manifold.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
6001-8000 hrs,
37-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.