106661-5342 ZEXEL 9 400 616 620 BOSCH INJECTION-PUMP ASSEMBLY 9400616620 1066615342 1671396766

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 620 9400616620

ZEXEL 106661-5342 1066615342

NISSAN-DIESEL 1671396766 1671396766

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Cross reference number

BOSCH 9 400 616 620 9400616620

ZEXEL 106661-5342 1066615342

NISSAN-DIESEL 1671396766 1671396766

Zexel num

Bosch num

Firm num

Name

106661-5342

9 400 616 620

1671396766 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6H * 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 3.65 3.6 3.7

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 12

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 119.2 117.2 121.2

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 105.7 102.7 108.7

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 240 240 240

Average injection quantity mm3/st. 10.5 9.2 11.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 14+-0.1

Pump speed r/min 40 40 40

Average injection quantity mm3/st. 106 106

Fixing the lever *

Rack limit *

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
----------
R1=14+-0.1mm SXL=12+0.2mm DL=6.9-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=22.5deg+-5deg

0000000901

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

----------
a=15deg+-5deg b=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)R = aa (2)Rack position bb
----------
aa=50mm bb=14+-0.1mm
----------
a=34.5deg+-5deg b=36.5deg+-5deg

Timing setting

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

----------
a=(30deg)

Information:

This Revised Service Letter replaces the 25May2010 Service Letter. Changes have been made to Termination Date.
TERMINATION DATE
31Jul2010
PROBLEM
The fuel inlet check valves, on the fuel injection pump, may fail on certain C6.6 Industrial Engines that are installed in specific OEM Applications. A failure of the inlet check valves could result in any of the following symptoms: failure to start, prevention of the engine from achieving full power, or a de-rate of the engine.
Before any repair is carried out, ensure the appropriate trouble shooting steps have been followed and carried out.
AFFECTED PRODUCT
Model Identification Number
C6.6 TIER 3 66605372, 5675-5704, 5718, 5720-5726, 5728-5731, 5733, 5735-5749, 5751-5771, 6005-6024, 6438, 7207-7215, 7221-7232, 7234-7240, 7268-7277, 7279-7288, 7428, 9732, 9746-9747, 9749-9754, 9756-9760, 9765, 9790-9809, 9823-9826, 9828-9839, 9841-9842, 9877-9894, 9896-9902, 9931-9937, 9939-9950, 9952-9955, 9959-9961, 10000, 10003-10005, 10007-10023, 10116, 10118-10149, 10438
PARTS NEEDED
Qty
Part Number Description
1 1113423 WASHER
1 2258019 GASKET-PUMP-HSG
3 2323149 WASHER-SEALING
1 2784138 PROTECTION KT
1 3368180 TUBE FUEL-INJ
1 3495736 PUMP GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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
Replace the existing fuel injection pump group with a new 349-5736 fuel injection pump group.
Refer to appropriate service manuals as necessary.
Rework Procedure:
1. Remove machine parts as necessary to gain sufficient access to the engine.
2. Remove existing fuel injection pump and replace it with a new 349-5736 fuel injection pump group. Refer to the Disassembly & Assembly Instruction RENR9722 Fuel Injection Pump - Remove and Install.
3. Ensure that all the warnings and notices are adhered to and safety practices are followed. Ensure that the protection caps are used during this operation to prevent issues with contamination.
4. Install all parts that were removed to gain access to the engine.
5. Check for leaks and repair as necessary.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.