106861-0813 ZEXEL 9 400 617 952 BOSCH INJECTION-PUMP ASSEMBLY 9400617952 1068610813 1671397572

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 952 9400617952

ZEXEL 106861-0813 1068610813

NISSAN-DIESEL 1671397572 1671397572

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Service parts 106861-0813 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106086-5411

3. GOVERNOR 105487-0851

4. SUPPLY PUMP 105217-6040

5. AUTOM. ADVANCE MECHANIS 105636-2760

6. COUPLING PLATE 105662-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4880

11. Nozzle and Holder 1660097015

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE

105015-4530

15. NOZZLE SET

Include in #1:

106861-0813 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 617 952 9400617952

ZEXEL 106861-0813 1068610813

NISSAN-DIESEL 1671397572 1671397572

Zexel num

Bosch num

Firm num

Name

106861-0813

9 400 617 952

1671397572 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RD8 * 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 3.65 3.6 3.7

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 11.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 105.1 104.1 106.1

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.9+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 13.1 11.1 15.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 650--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 3 2.5 3.5

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 4 4 4

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Rack limit using the stop lever: R1 (4)Damper spring setting: DL (5)Main spring setting (6)Set idle sub-spring
----------
R1=11.6mm DL=5.6-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle
----------

----------
a=10deg+-5deg b=10deg+-5deg

0000000901

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

----------
a=24.5deg+-5deg b=38.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the hole at R = bb
----------
aa=11.6mm bb=32mm
----------
a=29.5deg+-5deg b=4deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

----------
a=(90deg)

Information:

Caterpillar: Confidential Yellow
PSP FOR FUEL INJECTION LINE FAILURES ON 627E, 627E PP AND 637E SCRAPERS - MAILED WORLDWIDE EXCEPT BRAZIL
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.
U-35 A-20 AU-22 E-18 O-21 1252 PS4200 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4200" as Part Number and "7755" as Group Number. Termination Date
February 28, 1989
Problem
The fuel injection lines on 627E, 627E PP and 637E Scrapers may crack as a result of excessive vibration. New fuel injection lines and supporting brackets can be installed.
Affected Product
Model Identification Number 627E 6EBl - 513 627E PP 6GB513 - 177, 579-582, 584, 585, 587, 588, 590-603 637E 1FB1 - 338, 341-348, 350-352 1JB1 - 548, 550, 553, 555, 556, 558-561, 563
Parts Needed
1 - 7C9564 Line As. 1 - 7C9565 Line As. 1 - 7C9566 Line As. 11 - 1W9168 Clamp 8 - 5P4939 Screw As. 11 - lW9169 Clamp 1 - 9Y1586 Bracket As. 1 - 9Y1653 Bracket As. 3 - 9N3388 Screw 1 - 9Y2681 Bar (as needed) The 9Y2681 Bar is only needed if the engine is not equipped with heat shields.
Action Required
Install the new parts as shown in the attached illustration. It is important that the 1W9168 and 1W9169 Clamps be installed at the locations shown in the illustration.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first 0-2500