Information injection-pump assembly
ZEXEL
106691-0540
1066910540
NISSAN-DIESEL
1679096566
1679096566
Rating:
Service parts 106691-0540 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-96511
12.
Open Pre:MPa(Kqf/cm2)
22.6{230}
15.
NOZZLE SET
Include in #1:
106691-0540
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106691-0540
1066910540
NISSAN-DIESEL
1679096566
1679096566
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 8-3-600
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
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
3.65
3.6
3.7
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
A
Rack position
10
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
144
142
146
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
32
32
Boost pressure
mmHg
240
240
Injection quantity adjustment_02
Adjusting point
E
Rack position
4.6+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
13.7
12.7
14.7
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
300
300
300
Rack position
9.2
Boost pressure
kPa
6.7
4
9.4
Boost pressure
mmHg
50
30
70
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
10.7+-0.
1
Boost pressure
kPa
14.7
10.7
18.7
Boost pressure
mmHg
110
80
140
Boost compensator adjustment_03
Pump speed
r/min
300
300
300
Rack position
(11.3)
Boost pressure
kPa
18.7
18.7
18.7
Boost pressure
mmHg
140
140
140
Timer adjustment
Pump speed
r/min
980--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
930
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1050
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
1
0.5
1.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
(4)Excessive fuel lever setting (boost pressure 0)
(5)Rack difference between N = N1 and N = N2
(6)Set idle sub-spring
(7)Main spring setting
----------
K=9 BCL=(2.1)mm N1=1050r/min N2=650r/min
----------
----------
K=9 BCL=(2.1)mm N1=1050r/min N2=650r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(3deg)+-5deg b=(15deg)+-5deg
----------
----------
a=(3deg)+-5deg b=(15deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
0000001101
N:Normal
B:When boosted
(1)Rack position = aa at boost pressure = 0.
----------
aa=10.7+-0.1mm
----------
a=(8deg) b=(18deg)
----------
aa=10.7+-0.1mm
----------
a=(8deg) b=(18deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
20Oct2015
U-557
A-401
D-483
O-483
TM-15
TA-4
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 20R-0476 INJECTOR ASSEMBLIES FROM DEALER PARTS STOCK
7750 PI70592
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
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.
TERMINATION DATE
31Jan2016
PROBLEM
All 20R-0476 Injector Assemblies in dealer parts stock need to be inspected for the date code. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock. These injector as may have a nozzle assembly marked 2645K015 which is not correct. (Image1 = Incorrect) The correct nozzle assembly should be marked 2645K016. (Image2 = Correct) These two nozzles are not interchangeable.
ACTION REQUIRED
Inspect the date code on all 20R-0476 Injector Assemblies in dealer parts stock. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.