106691-0590 ZEXEL 9 400 610 995 BOSCH INJECTION-PUMP ASSEMBLY 9400610995 1066910590 1679096577

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 995 9400610995

ZEXEL 106691-0590 1066910590

NISSAN-DIESEL 1679096577 1679096577

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Service parts 106691-0590 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106069-7420

3. GOVERNOR 105407-6220

4. SUPPLY PUMP 105217-6010

5. AUTOM. ADVANCE MECHANIS 105681-0731

6. COUPLING PLATE 105662-1200

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6170

11. Nozzle and Holder 16600-96511

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

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-5800

15. NOZZLE SET

Include in #1:

106691-0590 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 610 995 9400610995

ZEXEL 106691-0590 1066910590

NISSAN-DIESEL 1679096577 1679096577

Zexel num

Bosch num

Firm num

Name

106691-0590

9 400 610 995

1679096577 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6T * K 14CA INJECTION PUMP ASSY PE6P,6PD PE

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 3.65 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 10

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 146.1 144.1 148.1

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_02

Adjusting point B

Rack position 10

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 147.9 141.9 153.9

Fixing the lever *

Boost pressure kPa 23.3 23.3

Boost pressure mmHg 175 175

Injection quantity adjustment_03

Adjusting point C

Rack position 9.8

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 134.1 131.1 137.1

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_04

Adjusting point D

Rack position 6+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 25.8 24.8 26.8

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 9.8

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

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position 10.7+-0. 1

Boost pressure kPa 12.7 12.7 12.7

Boost pressure mmHg 95 95 95

Boost compensator adjustment_04

Pump speed r/min 300 300 300

Rack position (11.4)

Boost pressure kPa 18 18 18

Boost pressure mmHg 135 135 135

Timer adjustment

Pump speed r/min 900+80

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1080

Advance angle deg. 1 0.5 1.5

Remarks
Finish

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)Main spring setting (6)Set idle sub-spring
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K=12 BCL=(1.6)mm
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Speed control lever angle

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

----------
a=3deg+-5deg b=17deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
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----------
a=26deg+-5deg b=53deg+-5deg

0000001101

N:Normal B:When boosted (1)Rack position = aa (at boost pressure bb)
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aa=10.7+-0.1mm bb=0
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a=(8deg) b=(18deg)

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
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L=5.7mm
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a1=B a2=- a3=- a4=- r1=650r/min r2=- r3=- r4=- Q1=146.1+-2mm3/st Q2=- Q3=- Q4=- c1=+-4% c2=- c3=- c4=- a5=22 a6=21 a7=- a8=- a9=- a10=- a11=- a12=- a13=- a14=- a15=- r5=1100r/min r6=1050r/min r7=- r8=- r9=- r10=- r11=- r12=- r13=- r14=- r15=- R5=1170+-27r/min R6=1120+-26r/min R7=- R8=- R9=- R10=- R11=- R12=- R13=- R14=- R15=-

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:

Introduction
This Special Instruction contains the necessary procedure in order to install unit injectors for 3114, 3116, and 3126 MUI engines.Removal and Installation Procedure
Note: To avoid damage to the unit injector during removal of the unit injector from the cylinder head, refer to the Service Manual for the removal procedure of the unit injector.Use the latest process for servicing the unit injector sleeves in the cylinder head before you install replacement unit injectors. Refer to the Service Manual and other service news articles in order to find the latest service information, including new tools and procedures.Before a new unit injector or a remanufactured unit injector is installed into an engine, take adequate precautions in order to clean the internal fuel lines and the unit injector sleeve. Also, install a new Caterpillar high efficiency fuel filter.Lubricate the injector rack bar with clean diesel fuel or 1U-8265 Penetrating Oil .
Illustration 1 g02144296
Incorrect testing procedure for the tappet springDo not depress the tappet spring. Refer to Illustration 1. Do not force the injector rack bar in and out since this action may damage the internal parts of the unit injector. A tight rack on a unit injector that is not installed in the engine is not an indication of a faulty unit injector. Forcing the injector rack bar in and out may cause the unit injector to become damaged. Forcing the injector rack bar in and out may possibly void all the warranty.Do not test the unit injectors prior to engine installation. The unit injectors are tested 100% at the factory and Pop Testing may contaminate the unit injector.Before you install the unit injector, apply clean engine oil on the O-ring seals for ease of installation.Install the unit injector according to the procedure in the Service Manual by using 173-1530 Injector Seating Tool . Tighten the unit injector clamp retaining bolt to a torque of 12 3 N m (9 2 lb ft).Verify the following parameters and settings according to the procedures in the Service Manual: unit injector synchronization, fuel setting, fuel timing and valve lash. Adjust the parameters and settings in order to meet specifications only.