Information injection-pump assembly
BOSCH
9 400 610 732
9400610732
ZEXEL
101607-9540
1016079540
NISSAN-DIESEL
16713Z6510
16713z6510
Rating:
Service parts 101607-9540 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z6003
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/22.6{230}
14.
NOZZLE
Cross reference number
BOSCH
9 400 610 732
9400610732
ZEXEL
101607-9540
1016079540
NISSAN-DIESEL
16713Z6510
16713z6510
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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-8921
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
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.7
3.65
3.75
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.8
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
95
93.4
96.6
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
Z
Rack position
9.5+-0.5
Pump speed
r/min
280
280
280
Average injection quantity
mm3/st.
12
11
13
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
800
800
800
Average injection quantity
mm3/st.
95
94
96
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.9
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
100.5
96.5
104.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
125
125
135
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
970--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
920
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
(1000)
Advance angle
deg.
1.5
1
2
Timer adjustment_04
Pump speed
r/min
1160
Advance angle
deg.
1.5
1
2
Timer adjustment_05
Pump speed
r/min
1450
Advance angle
deg.
7
6.5
7.5
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)RACK LIMIT
----------
T1=L08
----------
----------
T1=L08
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=39mm
----------
a=6.5deg+-5deg b=35deg+-3deg
----------
aa=39mm
----------
a=6.5deg+-5deg b=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)No return spring
----------
aa=32mm
----------
a=10deg+-5deg b=40deg+-5deg
----------
aa=32mm
----------
a=10deg+-5deg b=40deg+-5deg
0000001501 LEVER
(a) Speed lever
(B) Accelerator lever
(C) Accelerator lever stopper bolt
1. Accelerator lever setting method
With the speed lever in the idling position, back off the accelerator lever stopper bolt L1 from where it contacts point a.
----------
r1=39mm r2=38mm L1=1+0.5mm
----------
----------
r1=39mm r2=38mm L1=1+0.5mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(80deg)
----------
----------
a=(80deg)
Information:
Table 1
Special-Purpose Cat Lubricants
Item Size
6V-4876 Lubricant(1) 500 g (17.6 oz)
5P-3931 Thread Compound(2) 150 g (5.3 oz)
(1) Recommended for use on typical components such as head bolt threads and washers.
(2) Recommended for mating connectors such as exhaust manifold studs and exhaust manifold nuts.
Table 2
UV Visible Dyes for Leak Detection
Part Number Description Size Dosage
To detect oil leaks in engines, transmissions, hydraulic systems
1U-5572 Oil Glo 22 Additive 28.4 gram (1 ounce) bottle 28.4 gram (1 ounce) per 7.58 L (2 US gal) of oil
1U-5573 Oil Glo 22 Additive 0.47 L (1 pint) bottle 28.4 gram (1 ounce) per 7.58 L (2 US gal) of oil
To detect fuel leaks or suspected fuel dilution
1U-5574 Gas Glo 32 Additive 28.4 gram (1 ounce) bottle 28.4 gram (1 ounce) per 37.9 L (10 US gal) of gasoline or diesel fuel
1U-5575 Gas Glo 32 Additive 0.47 L (1 pint) bottle 28.4 gram (1 ounce) per 37.9 L (10 US gal) of gasoline or diesel fuel
To detect cooling system leaks
1U-5576 Water Glo 23 Additive 28.4 gram (1 ounce) bottle 28.4 gram (1 ounce) per 151.5 L (40 US gal) of water
1U-5577 Water Glo 23 Additive 0.47 L (1 pint) bottle 28.4 gram (1 ounce) per 151.5 L (40 US gal) of water The dyes must be used with a special Glo Gun to detect the leaks. Consult with your local Cat dealer for availability.