106861-0823 ZEXEL 9 400 617 953 BOSCH INJECTION-PUMP ASSEMBLY 9400617953 1068610823 1670097569

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 953 9400617953

ZEXEL 106861-0823 1068610823

NISSAN-DIESEL 1670097569 1670097569

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Service parts 106861-0823 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106086-5610

3. GOVERNOR 105306-0861

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 105100-4550

11. Nozzle and Holder 1660097012

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

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE 105015-4250

15. NOZZLE SET

Include in #1:

106861-0823 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 617 953 9400617953

ZEXEL 106861-0823 1068610823

NISSAN-DIESEL 1670097569 1670097569

Zexel num

Bosch num

Firm num

Name

106861-0823

9 400 617 953

1670097569 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 11.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 109 108 110

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.7+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 18.6 16.6 20.6

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 600

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 1

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.9 1.4 2.4

Timer adjustment_04

Pump speed r/min 1250+-25

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Rack limit using stop lever
----------
DL=5.1-0.5mm
----------

0000000901

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

----------
a=16deg+-5deg b=24deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=15deg+-5deg b=34deg+-3deg

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 INSTALLING NEW FUEL INJECTION LINE BRACKETS AND CLAMPS ON CERTAIN D8L TRACTORS, D9N TRACTORS, 589 PIPELAYERS, 631E SCR APERS, 637E SCRAPERS, 657E SCRAPERS, 768C TRACTORS, 769C TRUCKS, 834B TRACTORS, AND 988B LOADERS - PS4428 - MAILED US AND CA NADA, CACO, COFA, BRAZIL, CFEL, COSA
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-63 A-35 AU-38 B-13 E-39 O-54 1252 PS4428 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 "PS4428" as Part Number, "7755" as Group Number, and "96" as Description Code. Termination Date
March 31, 1991
Problem
The fuel lines on certain D8L Tractors, D9N Tractors, 589 Pipelayers, 631E Scrapers, 637E Scrapers, 657E Scrapers, 768C Tractors, 769C Trucks, 834B Tractors, and 988B Loaders may fail. New brackets and clamps can be installed to increase the service life of the fuel injection lines.
Affected Product
Model Identification Number D8L 7YB962 7JC778 D9N 1JD1288, 1295, 1296, 1298-1356, 1358, 1361-2039, 2045, 2048, 2049, 2052 589 31Z423-452 631E 1AB965-1198, 1209 637E 1FB361-416, 418, 422 1JB612-724 657E