Information injection-pump assembly
BOSCH
9 400 610 804
9400610804
ZEXEL
101696-9480
1016969480
NISSAN-DIESEL
16713Z6513
16713z6513
Rating:
Service parts 101696-9480 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5664
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 804
9400610804
ZEXEL
101696-9480
1016969480
NISSAN-DIESEL
16713Z6513
16713z6513
Zexel num
Bosch num
Firm num
Name
9 400 610 804
16713Z6513 NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
FE6TB K 14BF INJECTION PUMP ASSY PE6AD PE
FE6TB K 14BF INJECTION PUMP ASSY PE6AD PE
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
EF/8511/9A
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.
103.5
101.5
105.5
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
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
6.2
9.8
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(13.2)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
103.5
102.5
104.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
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
107.8
114.2
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
6)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
75
71.8
78.2
Fixing the lever
*
Boost pressure
kPa
36.7
36.7
Boost pressure
mmHg
275
275
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.1
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
56
52.8
59.2
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.
90
90
110
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
R2-1.1
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
R2(R1-0.
6)
Boost pressure
kPa
23.3
23.3
23.3
Boost pressure
mmHg
175
175
175
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=L11 BCL=1.1+-0.1mm
----------
----------
T1=L11 BCL=1.1+-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=36mm
----------
a=25deg+-5deg b=40.5deg+-3deg
----------
aa=36mm
----------
a=25deg+-5deg b=40.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Without 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 the No. 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
PROBLEM
On certain C175-16 and C175-20 Generator Sets the 276-1242 4 pin connector that connects the engine harness to the individual cylinder injector harnesses may not be fully latched do to a damaged connector locking tab.
AFFECTED PRODUCT
Model Identification Number
C175-16 WYB00649-00652, 656, 664-665, 1231-1232, 1237, 1241, 1243, 1249, 1253-1254, 1413, 1417, 1424, 1426, 1431, 1434, 1436, 1438, 1476, 1478-1484, 1508, 1564, 1566, 1569-1570, 1573-1574, 1578, 1610, 1612, 1614, 1622, 1625, 1627, 1630, 1825-1826, 1840-1841, 1846-1853, 1857-1860, 1862-1863, 1869-1871, 1873, 1876-1878, 1885, 1888-1891, 1895, 1899, 1904-1909, 1911, 1914-1920, 1925-1927, 1929, 1931-1932, 1936-1940, 1954, 1956, 1958, 2075, 2084, 2087-2088, 2091-2092, 2095-2096, 2098, 2100-2105, 2108-2109, 2112-2113, 2115-2116, 2118, 2127-2129, 2136-2142, 2179, 2182-2185, 2189, 2192-2193, 2195-2196, 2198, 2200, 2203, 2206-2209, 2214, 2227, 2229, 2232-2233, 2244, 2246, 2248-2257, 2332, 2337, 2342, 2352-2353, 2355-2356, 2359, 2362-2364, 2370-2371, 2416, 2437, 2470, 2475, 2479, 2481, 2493, 2500
C175-20 BXR01781, 1798-1807, 1809, 1826, 1828, 1944-1950, 1953-1956, 1959-1960, 1962, 2013-2014, 2026-2027, 2029, 2036, 2042-2046, 2048-2050, 2055-2058
PARTS NEEDED
Qty
Part Number Description
1 4C6389 TUBING-HEAT SHRI
1 1134630 RECEPTACLE AS
1 2300940 SEAL-PIP
1 2761242 KIT-PLUG CONN
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
1. Inspect 276-1242 4 pin engine harness connector and check the connector locking tab for proper engagement with injector harness receptacle. Image 1 is a damaged locking tab. Image 2 is a good locking tab. If locking tab is found to be damage proceed with replacement.
2. Disconnect the 276-1242 4 pin engine harness connector from the 113-4630 injector harness receptacle at the cylinder head.
3. Remove and replace 276-1242 4 pin connector with new. Insure to reinstall 4C-6389 heat shrink on the connector.
4. Inspect the inside of 113-4630 injector harness receptacle mounted on cylinder head for debris, damage, or paint. If debris, damage, or paint is present, remove and replace 113-4630 injector harness receptacle with new.
Note: Always use a new valve cover gasket if removal of valve cover is required.
5. Reconnect new 276-1242 4 pin engine harness connector to the new 113-4630 injector harnesses receptacle. Insure the connector is fully seated, audible click is heard, lock tab in the proper position, and connector cannot be pulled out.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-600 hrs,
0-45 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.