Information injection-pump assembly
BOSCH
9 400 610 802
9400610802
ZEXEL
101696-9431
1016969431
NISSAN-DIESEL
16713Z6466
16713z6466
Rating:
Service parts 101696-9431 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5578
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 802
9400610802
ZEXEL
101696-9431
1016969431
NISSAN-DIESEL
16713Z6466
16713z6466
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
134424-1520
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-4-2-6-
3-5
Pre-stroke
mm
3.9
3.85
3.95
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
13.2
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
103
101
105
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
275
275
275
Average injection quantity
mm3/st.
8.6
6.8
10.4
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(13.2)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
103
102
104
Basic
*
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1+0.2)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
111.5
108.3
114.7
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1+0.
1)
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
85.5
82.3
88.7
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.3
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
61.5
58.3
64.7
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
89
89
109
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
R2-1.3
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1+0.
1)
Boost pressure
kPa
13.3
13.3
13.3
Boost pressure
mmHg
100
100
100
Timer adjustment
Pump speed
r/min
1170--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
450
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
(530)
Advance angle
deg.
0
0
0
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1120
Advance angle
deg.
0.5
Timer adjustment_05
Pump speed
r/min
1400
Advance angle
deg.
4.5
4
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
(4)Boost compensator stroke: BCL
----------
T1=K21 BCL=1.3+-0.1mm
----------
----------
T1=K21 BCL=1.3+-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=36mm
----------
a=25deg+-5deg b=39deg+-3deg
----------
aa=36mm
----------
a=25deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)No return spring
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
----------
aa=28mm
----------
a=20deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack limit adjustment
(1)Fix the rack at the rack limit position Ra.
(2)Install the shim (D) to the rod (C) and tighten nut (E).
(3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L.
(4)Release the rack fixing and mount the joint (B) and fix.
(5)At this time, confirm that the shim (D) does not interfere with the joint (B).
2. Rack sensor adjustment (-0420)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set the speed to N1 r/min.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.02 V, then tighten the nut (F).
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2mm N1=700r/min Ra=R1(13.2)mm
----------
----------
L=33-0.2mm N1=700r/min Ra=R1(13.2)mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
AFFECTED PRODUCT
Model Identification Number
C9 LFE00178-00180, 182, 193-194, 196, 2025, 2372-2375, 2585-2588, 2594-2595, 2710, 2714-2716, 2718-2722, 2725-2727, 2729, 2731-2741, 2743-2747, 2765-2784, 2831, 2833-2836, 2838-2839, 2841-2843, 2847-2852, 2855, 2857-2858, 2862, 2879, 2881-2886, 2888, 2890-2892, 2894-2896, 2898-2907, 2909, 2914, 2916-2918, 2920-2921, 2923-2924, 2926, 2928, 2931, 2934, 2937, 2986, 2988-2993, 2995-3043, 3045-3065, 3101-3106, 3110-3111, 3113, 3116, 3118, 3120, 3122, 3125, 3127-3129, 3132-3133, 3138, 3149-3168, 3204-3242, 3250, 3258-3343, 3345-3386, 3582-3584, 3590-3604, 3681-3730, 3732-3735, 3738-3739, 3741-3742, 3744-3749, 3791, 3793-3794, 3812-3831, 3866-3880, 3882-3897, 3899-3919, 3950-4020, 4026-4083, 4085-4118, 4121-4122, 4124-4151, 4153-4240, 4242, 4253-4278, 4281-4316, 4383-4384, 4387-4390, 4392-4395, 4398-4492, 4495-4497
PARTS NEEDED
Qty
Part Number Description
1 5734235 INJECTOR GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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
****Parts Stock ****
Remove all 387-9435 Fuel Injectors from dealer parts stock. Refer to the Parts Disposition.
****Affected Product****
Replace the failed 387-9435 Fuel Injector with a 573-4235 Fuel Injector. Refer to the Disassembly and Assembly, RENR7460, "Unit Injector - Remove", and "Unit Injector - Install", for rework instructions.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all parts removed from dealer parts stock.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-192 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job
PARTS DISPOSITION
****Parts Stock****
Hold all 387-9435 Fuel Injectors for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.