106861-0687 ZEXEL 9 400 617 948 BOSCH INJECTION-PUMP ASSEMBLY 9400617948 1068610687 1670097565

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 948 9400617948

ZEXEL 106861-0687 1068610687

NISSAN-DIESEL 1670097565 1670097565

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Cross reference number

BOSCH 9 400 617 948 9400617948

ZEXEL 106861-0687 1068610687

NISSAN-DIESEL 1670097565 1670097565

Zexel num

Bosch num

Firm num

Name

106861-0687

9 400 617 948

1670097565 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RD8T * 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 1-8-7-5- 4-3-6-2

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 11.1

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 134 131 137

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 136 134 138

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 10.4

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 93.8 91.8 95.8

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 5.6+-0.5

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 17 15 19

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10.4

Boost pressure kPa 9.3 6.6 12

Boost pressure mmHg 70 50 90

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 10.9

Boost pressure kPa 14.7 12 17.4

Boost pressure mmHg 110 90 130

Boost compensator adjustment_03

Pump speed r/min 500 500 500

Rack position 11.1

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 1

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.1 0.6 1.6

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)After completing adjustment of the broken line, set the lever at the unbroken line position. (2)Rack limit using the stop lever: R1 (3)Beginning of damper spring operation: DL (4)Boost compensator stroke: BCL
----------
R1=11.1mm DL=5.1-0.2mm BCL=0.7mm
----------

0000000901

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

----------
a=16deg+-5deg b=25deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
----------
aa=11mm
----------
a=13deg+-5deg b=33.5deg+-5deg

Information:

PROBLEM
The front suspension A-Frame bearing may not be receiving an adequate amount of grease on machines that are equipped with the factory fitted Automatic Lubrication System. An inadequate amount of grease supply to the bearing does not promote purging of grease through the joint, especially in severe applications. This may result in premature wear of the bearing.
A larger sized injector is available which increases the amount of grease that is supplied to the bearing
Note: This service letter covers machines with factory fitted Automatic Lubrication Systems only. Dealer installed Automatic Lubrications Systems are not covered.
AFFECTED PRODUCT
Model Identification Number
735B L4D00368, 372, 375-380, 384-403
T4P00253-00258, 268-271, 275-277, 280-282, 284-286, 290-292, 302, 304
740B L4E00374-00378, 380, 385, 390, 392-393, 401-403, 407-408, 411, 419, 429-430, 433-437, 440, 443-449, 451, 453-455, 459, 465, 469, 471, 478, 480, 489, 492, 505, 511, 517, 522-529, 533, 535, 543, 549-550, 558, 560, 563, 567, 570, 575-576, 584, 592, 609-610, 612-616, 622, 624-627, 633-634, 643, 666, 670-673, 679-682, 687-694, 701-702, 708, 710, 712, 715-716, 722, 726-728, 734-735, 738, 741-743, 745-746, 755-757, 760, 763, 768, 774, 777, 779, 784-785, 788-789, 792, 796-799, 802-803, 805, 810, 812-813, 816-817, 821-822, 826-828, 833, 837, 842, 851, 853, 857, 861, 865-867, 881-882, 885, 887, 890-891, 896, 900, 903-904, 909-910, 912-915, 917-919, 921, 924-925, 927, 932-933, 945-950, 955-957, 962-971, 976-980, 985
T4R00267-00273, 278, 282-283, 289, 294, 299-300, 309-310, 322-323, 327, 339, 342, 348, 352, 354, 356, 359-360, 362-369, 371, 376-377, 393, 406, 423, 427, 431-432, 450, 518, 539-540, 543-546, 550, 557, 568, 581-582, 587-590
740B EJ L4F00383-00388
T4S00272-00274, 276-279, 282, 289-290, 296-299, 301, 304-309, 311
PARTS NEEDED
Qty
Part Number Description
1 1926212 INJECTOR
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 16% 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
See attached rework procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-8000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
(1). Remove the grease injector from the manifold that is located on the right side of the front chassis. See Image 1.1.1 for location.
(2). Install new 192-6212 Injector.
(3). Purge new injector by pressing the Test Switch on the Auto Lube pump. See Image 1.1.2 for test switch location.
(4). Install the grease line to the injector.
Image1.1.1
Image1.1.2