106661-5214 ZEXEL 9 400 616 613 BOSCH INJECTION-PUMP ASSEMBLY 9400616613 1066615214 1671396716

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 613 9400616613

ZEXEL 106661-5214 1066615214

NISSAN-DIESEL 1671396716 1671396716

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Buy INJECTION-PUMP ASSEMBLY 106661-5214 zexel genuine, new aftermarket engine parts with delivery

Service parts 106661-5214 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5410

3. GOVERNOR 105487-4050

4. SUPPLY PUMP 105217-1850

5. AUTOM. ADVANCE MECHANIS 105681-4310

6. COUPLING PLATE 105662-1200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7200

11. Nozzle and Holder 1660096516

12. Open Pre:MPa(Kqf/cm2) 14.7(150)/19.6(200)

13. NOZZLE-HOLDER 105031-4630

14. NOZZLE

105015-5290

15. NOZZLE SET

Include in #1:

106661-5214 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 613 9400616613

ZEXEL 106661-5214 1066615214

NISSAN-DIESEL 1671396716 1671396716

Zexel num

Bosch num

Firm num

Name

106661-5214

9 400 616 613

1671396716 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6 * K

Calibration Data:

Adjustment conditions

Test oil
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 8-3-600

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.95 3.9 4

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8.8

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 120.4 118.4 122.4

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 108 105 111

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point F

Rack position 5.6+-0.5

Pump speed r/min 240 240 240

Average injection quantity mm3/st. 8 6.7 9.3

Fixing the rack *

Remarks
Check

Injection quantity adjustment_04

Adjusting point G

Rack position 5.4+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 200+100

Advance angle deg. 1.6 1.1 2.1

Remarks
Start

Timer adjustment_02

Pump speed r/min 500-150

Advance angle deg. 0 0 0

Timer adjustment_03

Pump speed r/min 925+-30

Advance angle deg. 0 0 0

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using the stop lever: R1 (2)Excess fuel setting for starting: SXL (3)Damper spring setting: DL (4)Variable speed specification: idling adjustment (5)Main spring setting
----------
R1=15+0.2mm SXL=8.9+0.1mm DL=3.9-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Stopper bolt setting
----------
aa=275r/min
----------
a=30deg+-5deg b=21deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=15deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)R = aa (2)Rack position bb
----------
aa=50mm bb=15+0.2mm
----------
a=37.5deg+-5deg b=39.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)

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