Information injection-pump assembly
ZEXEL
101608-9960
1016089960
NISSAN-DIESEL
16713Z6912
16713z6912
Rating:
Service parts 101608-9960 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5700
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/20.6{210}
15.
NOZZLE SET
Include in #1:
101608-9960
as INJECTION-PUMP ASSEMBLY
Include in #2:
104107-1140
as _
Cross reference number
ZEXEL
101608-9960
1016089960
NISSAN-DIESEL
16713Z6912
16713z6912
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
105780-8310
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2240
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
131424-8120
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
1-4-2-6-
3-5
Pre-stroke
mm
3.5
3.45
3.55
Beginning of injection position
Drive side NO.1
Drive 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
12.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
53.5
51.5
55.5
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
260
260
260
Average injection quantity
mm3/st.
9
7.2
10.8
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(13.4)
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
55.5
54.5
56.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-1.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
53.5
49.5
57.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
145
145
155
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
1450
Advance angle
deg.
6
5.7
6.3
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)RACK LIMIT
----------
T1=N43
----------
----------
T1=N43
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=25deg+-5deg b=41deg+-3deg
----------
aa=36mm
----------
a=25deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=42mm
----------
a=40deg+-5deg b=25deg+-5deg
----------
aa=42mm
----------
a=40deg+-5deg b=25deg+-5deg
0000001501 RACK SENSOR
G:Red paint
H:Pump end face
P/N: part number of suitable shim
(1)Threaded type rack block
(2)Welded type rack block
Rack sensor adjustment
1. Threaded type rack sensor (-5*20, P type, no TICS rack limit).
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the pump lever.
(3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1.
(4)Fix using the nut (F).
(5)Affix the caution plate to the upper part of the joint (B).
(6)Apply (G) at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the end surface of the pump (H) and the joint (B)
2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads.
Screw in to the end from (the position where the bobbin (A) is rotated 9 turns).
Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(13.4)mm N1=1450r/min V1=3+-0.01V
----------
----------
Ra=R1(13.4)mm N1=1450r/min V1=3+-0.01V
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
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.
COMPLETION DATE
TERMINATION DATE
28Feb2007 31Aug2007
PROBLEM
The torque on the 100-6920 Direct Injection Fuel Nozzle Adapters may be out of specification.
AFFECTED PRODUCT
Model Identification Number
3408C TAM00350-00351
3412 38S24043
BCS02130
3412C 9BR03238
9EP03871, 3969-3970, 3972-3973
DJN01044-01070, 1074-1076, 1081, 1087
RLR00339, 341-342
TFT00565-00583
PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
Remove valve covers, fuel lines and fuel nozzles. Tighten the 100-6920 Direct Injection Fuel Nozzle Adapters to 200 +/- 14 Nm (150 +/- 10 lb ft). Reassemble engine. For detailed instructions, refer to the procedure in the Disassembly and Assembly manual. Test engine for proper operation after reassembly.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 3.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR TIGHTENING THE DIRECT INJECTION FUEL NOZZLE ADAPTERS
MODELS INVOLVED - Certain 3408 and 3412 Engines
Dear Caterpillar Product Owner:
The torque on the Direct Injection Fuel Nozzle Adapters may be out of specification. The Direct Injection Fuel Nozzle Adapters need to be tightened to the correct torque on the products listed below. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 24Aug2006 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 24Aug2006 Service Letter