106871-0060 ZEXEL 9 400 618 007 BOSCH INJECTION-PUMP ASSEMBLY 9400618007 1068710060 1679097502

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 007 9400618007

ZEXEL 106871-0060 1068710060

NISSAN-DIESEL 1679097502 1679097502

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Service parts 106871-0060 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5121

3. GOVERNOR 105407-0700

4. SUPPLY PUMP 105237-6350

5. AUTOM. ADVANCE MECHANIS 105645-5080

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-4760

11. Nozzle and Holder 1660097005

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

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE 105015-3440

15. NOZZLE SET

Include in #1:

106871-0060 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 007 9400618007

ZEXEL 106871-0060 1068710060

NISSAN-DIESEL 1679097502 1679097502

Zexel num

Bosch num

Firm num

Name

106871-0060

9 400 618 007

1679097502 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RD8T * K 14CD PE8P 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 1-8-7-5- 4-3-6-2

Pre-stroke mm 3 2.95 3.05

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 13.6+-0. 5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 204 198 210

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 13.6+-0. 5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 187.5 181.5 193.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 13.6

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 171 169 173

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 6.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 17.5 15.5 19.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 600

Advance angle deg. 1

Timer adjustment_03

Pump speed r/min 750

Advance angle deg. 1.2 0.7 1.7

Timer adjustment_04

Pump speed r/min 1150

Advance angle deg. 3.5 3.5 4.5

Timer adjustment_05

Pump speed r/min 1250

Advance angle deg. 4 4 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)RACK LIMIT: RAL (4)Damper spring setting
----------
K=10 RAL=14.3+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=12deg+-5deg b=32deg+-3deg c=27.5deg+-5deg

Stop lever angle

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

----------
a=27.5deg+-5deg b=53deg+-5deg

Information:

Caterpillar Reference Material
The following literature can be obtained through any Caterpillar dealer.Oil
SEBD0640, Oil and Your EnginePEDP7122, Question & Answer BookletPEDP1129, Listen To Your OilPEHP6001, How to Take a Good Oil SampleSEBU6251, Lubricant RecommendationsPEHP1027, Product Data Sheet for Cat Diesel Engine Oil (CD)PEHP0002, Product Data Sheet for Cat Molybdenum Grease (MPGM)PEHP0003, Product Data Sheet for Cat Lithium Grease (MPGL)PEHP0017, Product Data Sheet for Cat Special Purpose Grease (SPG)PEWP9733, Cat Fluids SelectorPEDP7105, Scheduled Oil SamplingFuel
SEBD0717, Diesel Fuels and Your EngineCoolant
SEBD0518, Know Your Cooling SystemSEBD0970, Coolant and Your EngineMiscellaneous
SEBF8029, Index to Guidelines for Reusable Parts and Salvage OperationsSEBF8062, Guideline for Reusable Parts - Cleaning and Inspection of Air FiltersSEHS9031, Storage Procedure for Caterpillar ProductsSENR5226, Service Manual (EMCP)SEBU6150, SR4 Generators and Control Panels Operation and Maintenance ManualSEBU6918, SR4B Generators and Control Panels Operation and Maintenance ManualSENR7337, Service Manual, 3408 and 3408B Industrial and Marine EnginesSENR7405, Service Manual, 3412 Industrial and Marine EnginesSENR2559, Service Manual, 3408 and 3412 Generator Set EnginesSEHS7654, Alignment-General InstructionsSEHS9124, Cleaning and Drying of Caterpillar Electric Set GeneratorsLEBH9324, Agricultural and Material Handling Application and Installation GuideSEHS7292, Use of 5P4150 Nozzle Testing GroupSEHS8622, Using the FT1984 Air-To-Air Aftercooler Leak Test GroupSEHS7795, Use of Pump & Governor Tool GroupSEHS8024, Governor Adjusting Tool GroupSEHS8094, Use of Nozzle Puller GroupAdditional Reference Material
ASTM D2896- TBN MeasurementsASTM D21768- Worked PenetrationASTM D2982B- Ethylene Glycol ContentASTM D3828A- Fuel DilutionASTM D445- ViscosityASTM D893- InsolublesASTM 498589- GM-6038M SpecificationASTM Specs can normally be obtained from your local technological society, library or college.SAE J313- Diesel FuelsSAE J754- NomenclatureSAE J183- ClassificationSociety of Automotive Engineers (SAE) Specs can be found in your SAE handbook or can be obtained from your local library, college, or technological society.* SAE handbooks can be obtained directly from:SAE International
400 Commonwealth Drive
Warrendale, PA USA 15096-0001
Engine Manufacturers Association (EMA) information for lube oil selection can be obtained from your local library, college or technological society, or contact:* Engine Manufacturers AssociationLubricating Oils Data Book
401 N. Michigan Ave. Ste. 2400
Chicago, IL 60611
(312) 644-6610 ext. 3626