106661-5580 ZEXEL 9 400 616 632 BOSCH INJECTION-PUMP ASSEMBLY 9400616632 1066615580 1671396075

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 632 9400616632

ZEXEL 106661-5580 1066615580

NISSAN-DIESEL 1671396075 1671396075

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Service parts 106661-5580 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-1300

3. GOVERNOR 105427-0470

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105614-4320

6. COUPLING PLATE 105662-0761

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4570

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 22.6(230)

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-4170

15. NOZZLE SET

Include in #1:

106661-5580 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 632 9400616632

ZEXEL 106661-5580 1066615580

NISSAN-DIESEL 1671396075 1671396075

Zexel num

Bosch num

Firm num

Name

106661-5580

9 400 616 632

1671396075 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6T04 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 132424-0620

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 3.2 3.15 3.25

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 11.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 149.6 147.6 151.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

Injection quantity adjustment_02

Adjusting point D

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 10 12

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10.3

Boost pressure kPa 6.7 4.7 8.7

Boost pressure mmHg 50 35 65

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (11.5)

Boost pressure kPa 20 13.3 26.7

Boost pressure mmHg 150 100 200

Timer adjustment

Pump speed r/min 350

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 2.5 2 3

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Load control lever's full position (2)Speed control lever full position (3)Target notch: K (4)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure) (5)Boost compensator stroke: BCL (6)Set the load lever at the stop position.
----------
K=17 L1=12.1+-0.1mm BCL=(1.2)mm
----------

Speed control lever angle

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

----------
a=12deg+-5deg b=27deg+-5deg

0000000901

F:Full load I:Idle S:Stop (1)Rack position aa or less, pump speed bb (2)Use the hole above R = cc (3)Without return spring
----------
aa=5.6mm bb=0r/min cc=55mm
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a=23deg+-5deg b=24deg+-5deg c=32deg+-3deg

0000001101

N:Normal B:When boosted (1)Rack position = aa at boost pressure 0. (2)Drive side
----------
aa=12.1+-0.1mm
----------
a=10deg+-5deg b=(20deg)

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=6.1mm
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a1=A a2=B a3=C a4=D a5=- a6=- r1=750r/min r2=750r/min r3=750r/min r4=750r/min r5=- r6=- Q1=152+-2mm3/st Q2=149.6+-2mm3/st Q3=139+-2mm3/st Q4=120.1+-2mm3/st Q5=- Q6=- c1=+-4% c2=+-4% c3=+-4% c4=+-4% c5=- c6=- a7=23 a8=22 a9=21 a10=20 a11=19 a12=18 a13=17 a14=16 a15=15 a16=14 a17=13 a18=12 a19=- a20=- r7=1150r/min r8=1100r/min r9=1050r/min r10=1000r/min r11=950r/min r12=900r/min r13=850r/min r14=800r/min r15=750r/min r16=700r/min r17=650r/min r18=600r/min r19=- r20=- R7=1235+-28r/min R8=1180+-27r/min R9=1130+-26r/min R10=1075+-25r/min R11=1020+-23r/min R12=965+-22r/min R13=915+-22r/min R14=860+-20r/min R15=805+-18r/min R16=750+-17r/min R17=695+-16r/min R18=645+-15r/min R19=- R20=-

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:

Illustration 5 g06198951
70-Pin connector
(5) Pin 4
(6) Pin 24
Illustration 6 g06198953
40-Pin connector
(7) Pin 4
(8) Pin 24
Using the appropriate terminal extraction tool, remove the red and black wires from positions 4 and 24 of the connector. Refer to Illustration 5 and 6.
Route the extracted wires out of the engine harness and insert the wires into 3E-3370 Connector Receptacle As supplied with 517-0586 Engine Harness As. Red wire in position 1 and Black wire in position 2.Note: Minor cutting of the boot may be required.
Install the Red wire from 517-0586 Engine Harness As into position 4 of the Machine Interface Connector and install the Black wire into position 24 of the connector.
Illustration 7 g06237613
70 Pin Harness
(A) Pin 4 From Machine Interface Harness Connector
(B) Pin 24 From Machine Interface Harness Connector
(C) Pyrometer Harness Interface Connector
(D) Machine Interface Connector
Illustration 8 g06237606
40 Pin Harness
(A) Pin 4 From Machine Interface Harness Connector
(B) Pin 24 From Machine Interface Harness Connector
(E) Flying Power Leads from 514-3813 Harness As to 2 Pin Connector
(F) Machine Interface Connector
If the Pyrometer Interface Harness connector is a 70 pin, Route 517-0586 Engine Harness As to the Pyrometer Harness Interface connector and install Red wire into position 70 and the Black wire into position 69. If the Pyrometer Interface Harness connector is a 40 pin, install the Red wire into pin 1 of a 2-pin receptacle and the Black wire into pin 2. This connector will then connect to G-C3 of 514-3813 Engine Harness As.
With the engine powered, use a digital multimeter to verify that 24V power is present at the Pyrometer Harness Interface connector.Installation of 510-4068 Electronic Control Gp (Pyrometer)
Attach 489-3081 Harness As to 510-4068 Electronic Control Gp (Pyrometer) and the Pyrometer Interface Connector. Using 489-3081 Engine Harness As as a gauge, temporarily install the module on an appropriate place as per the choice of installer.Installation of 505-1731 Engine Harness As
If the engine under test is a 16 cylinder instead of a 20 cylinder, 505-1731 Engine Harness As can be installed between 489-3081 Engine Harness As and 510-4068 Electronic Control Gp.Installation of 489-3081 Engine Harness As
Perform the following procedure to install 489-3081 Engine Harness As:
Install 504-3341 Engine Harness As on the service port connector of 489-3081 Engine Harness As.
Route 504-3341 Engine Harness As to a safe location before performing tests.Note: Attach 140-9442 "Y" Adapter Cable As in order to see all the machine ECMs. Connect 504-3341 Monitor Harness As to "Y", connect other leg to Machine Service port and the third leg to Communication Adapter.Overview and Configuration On Caterpillar Electronic Technician (Cat ET)
This section will describe the overview and configuration setting on Cat ET.Cat ET Screen - Standard View
Perform the following instructions once the system is installed:
Connect to communications adapter and launch Cat ET.
Illustration 9 g06198935
After connecting, under "Available ECM(s)" select "Digital Pyrometer #1".
Illustration 10 g06199349
(9) Status button
Select the "Status" (9) button in the toolbar and then the parameters of "Digital Pyrometer #1" will appear.
Selecting "Engine Cylinder Temperature - 1"