Information injection-pump assembly
BOSCH
9 400 611 723
9400611723
ZEXEL
106871-1192
1068711192
ISUZU
1156031992
1156031992
Rating:
Service parts 106871-1192 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-328-0
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.1{225}
15.
NOZZLE SET
Include in #1:
106871-1192
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 723
9400611723
ZEXEL
106871-1192
1068711192
ISUZU
1156031992
1156031992
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4320
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-8-7-3-
6-5-4-2
Pre-stroke
mm
5.5
5.47
5.53
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
10.3
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
109
107.4
110.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
6.5+-0.5
Pump speed
r/min
420
420
420
Average injection quantity
mm3/st.
13.5
11.5
15.5
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
109
108
110
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.2
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
115
111
119
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Damper spring setting
----------
T1=AD64
----------
----------
T1=AD64
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8)deg t1=1.5--sec t2=1.5--sec
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(8)deg t1=1.5--sec t2=1.5--sec
----------
N1=950++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=42.5mm
----------
a=22.5deg+-5deg b=(34.5deg)+-3deg
----------
aa=42.5mm
----------
a=22.5deg+-5deg b=(34.5deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=37.5mm bb=0r/min cc=1.5+-0.3mm
----------
a=40deg+-5deg b=43deg+-5deg
----------
aa=37.5mm bb=0r/min cc=1.5+-0.3mm
----------
a=40deg+-5deg b=43deg+-5deg
0000001501 RACK SENSOR
Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=1150r/min Ra=R1(10.3)+1.2mm Vist=1.65+-0.14V
----------
----------
V1=5+-0.01V N1=1150r/min Ra=R1(10.3)+1.2mm Vist=1.65+-0.14V
----------
Timing setting
(1)Pump vertical direction
(2)Position of "Z" mark at the No 1 cylinder's beginning of injection (governor side)
(3)B.T.D.C.: aa
(4)-
----------
aa=4deg
----------
a=(180deg)
----------
aa=4deg
----------
a=(180deg)
Information:
PROBLEM
The existing diesel exhaust fluid manifold can fail on certain 2570D, 2670D, 563D, and 573D Wheel Feller Bunchers, and 525D, 535D, 545D, and 555D Wheel Skidders. If the existing DEF manifold fails it can lead to inducements and eventual engine shutdown.
AFFECTED PRODUCT
Model Identification Number
2570D D2500112-00114
2670D D2600208-00211
525D GKP00477-00524, 527
535D MTP00386-00448, 450-453
545D KGP00254-00284, 287
555D PGY00153-00159
563D D6300115-00146
573D D7300209-00226
PARTS NEEDED
Qty
Part Number Description
1 3915262 GASKET
1 5280527 MANIFOLD GP
1 DCUSOFTWARE DCU SOFTWARE
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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
Update the Engine and DCU software files to the latest available in SIS Web. Replace the existing diesel exhaust fluid manifold with the 528-0527 diesel exhaust fluid manifold. Use a new 391-5262 gasket when installing a new manifold.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
6001-8000 hrs,
37-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.