Information injection-pump assembly
BOSCH
F 01G 09U 0A7
f01g09u0a7
ZEXEL
106871-5570
1068715570
Rating:
Service parts 106871-5570 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-97160
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.6{230}
14.
NOZZLE
Include in #1:
106871-5570
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 01G 09U 0A7
f01g09u0a7
ZEXEL
106871-5570
1068715570
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
131425-0120
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
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
1-8-7-5-
4-3-6-2
Pre-stroke
mm
4.4
4.37
4.43
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 1-5 deg. 135 134.75 135.25
Cal 1-5 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-3 deg. 225 224.75 225.25
Cal 1-3 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 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
Rack position
(13.2)
Vist
V
1.87
1.87
1.87
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
128
126
130
Max. variation between cylinders
%
0
-4
4
Basic
*
Injection quantity adjustment_02
Rack position
(8.6)
Vist
V
2.6
2.5
2.7
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
16
14
18
Max. variation between cylinders
%
0
-10
10
Governor adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
At Q=169+-2 (mm3/st) / N=700 (r/min), start of advance
At Q=169+-2 (mm3/st) / N=700 (r/min), start of advance
Governor adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.3
Remarks
Q=169+-2 (mm3/st) / N=700 (r/min)
Q=169+-2 (mm3/st) / N=700 (r/min)
Governor adjustment_03
Pump speed
r/min
(750)
Advance angle
deg.
2
1.7
2.3
Remarks
Q=169+-2 (mm3/st) / N=700 (r/min)
Q=169+-2 (mm3/st) / N=700 (r/min)
Governor adjustment_04
Pump speed
r/min
850
Advance angle
deg.
2
1.7
2.3
Remarks
Q=97+-2 (mm3/st) / N=850 (r/min)
Q=97+-2 (mm3/st) / N=850 (r/min)
Governor adjustment_05
Pump speed
r/min
1000
Remarks
Q = 162+-2 (mm3/st) / N = 1100 (r/min), measure actual advance
Q = 162+-2 (mm3/st) / N = 1100 (r/min), measure actual advance
Governor adjustment_06
Pump speed
r/min
1100
Advance angle
deg.
7
6.7
7.3
Remarks
Q=162+-2 (mm3/st) / N=1100 (r/min), end of advance
Q=162+-2 (mm3/st) / N=1100 (r/min), end of advance
Test data Ex:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
0000000901
(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)
----------
----------
a=(90deg)
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 19 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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----------
----------
----------
Information:
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 "PS9436" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
Termination Date
March 31, 1999Problem
Engines may experience ingress of coolant to the fuel system or vice versa due to the degradation of the sleeve seal-o-rings and the unit injector seal-o-rings. The contamination of coolant into the fuel system affects engine performance and can cause injector seizure. Contamination of fuel in the cooling system may reduce cooling performance.
Affected Product
Model & Identification Number
The work outlined in this program is to occur once only for the following engines with a minimum of 300,000 liters of fuel burned. In most applications this generally corresponds to:
*Every 300,000 kms of engine life for B-Triple and Triple Road Trains.*Every 450,000 kms of engine life for B-Double and Double Road Trains.*Every 600,000 kms of engine life for Single Trailers.3406E (5EK1-Up 6TS1-Up 1LW1-Up 5DS1-Up )
Parts Needed
6 - 9X7317 SEAL-O RING (Lower Seal-0-ring of unit Injector),6 - 9X7418 SEAL-O RING (Upper Seal-0-ring of Unit Injector),6 - 9X7419 SEAL-O RING (Mddle Seal-0-ring of Unit Injector),6 - 9X7430 SEAL-O-RING (Upper Seat-0-ring of unit Injector Sleeve),12- 9X7431 SEAL-O-RING (Lower Seal-0-ring of unit Injector Sleeve, two per sleeve),Action Required
See the attached procedure.
Service Claim Allowances
This job varies by cab type.
*See labor breakdowns. Labor Hours By Cab Type Parts Disposition
Please return seal-o-rings packaged in plastic bags, with relevant history of the truck and engine, to:
Steve Keenan,
Application and Service Engineer-
Caterpillar of Australia.
Private Mailbag 4.
Tuilamarine. 3043.
Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
(1-Rework Procedure)Rework Procedure
1. Refer to attached parts book drawings.2. Obtain an ECM print-out from the Truck. Retain this print-out.3. Remove set of unit injectors. (Code 1290-010: refer p.109 of TRG for 3406E on highway truck engines;4. Drain and collect coolant.5. Remove and install set of unit injector sleeves (Code 1713-010: refer p. 111 of TRG).6. Replace injector body seals and sleeve seals. Return seals only as per parts disposition.7. Install set of unit injectors.8. Refill with coolant.9. Install set of unit injector sleeves.
Illustration 1.
Illustration 2.
Termination Date
March 31, 1999Problem
Engines may experience ingress of coolant to the fuel system or vice versa due to the degradation of the sleeve seal-o-rings and the unit injector seal-o-rings. The contamination of coolant into the fuel system affects engine performance and can cause injector seizure. Contamination of fuel in the cooling system may reduce cooling performance.
Affected Product
Model & Identification Number
The work outlined in this program is to occur once only for the following engines with a minimum of 300,000 liters of fuel burned. In most applications this generally corresponds to:
*Every 300,000 kms of engine life for B-Triple and Triple Road Trains.*Every 450,000 kms of engine life for B-Double and Double Road Trains.*Every 600,000 kms of engine life for Single Trailers.3406E (5EK1-Up 6TS1-Up 1LW1-Up 5DS1-Up )
Parts Needed
6 - 9X7317 SEAL-O RING (Lower Seal-0-ring of unit Injector),6 - 9X7418 SEAL-O RING (Upper Seal-0-ring of Unit Injector),6 - 9X7419 SEAL-O RING (Mddle Seal-0-ring of Unit Injector),6 - 9X7430 SEAL-O-RING (Upper Seat-0-ring of unit Injector Sleeve),12- 9X7431 SEAL-O-RING (Lower Seal-0-ring of unit Injector Sleeve, two per sleeve),Action Required
See the attached procedure.
Service Claim Allowances
This job varies by cab type.
*See labor breakdowns. Labor Hours By Cab Type Parts Disposition
Please return seal-o-rings packaged in plastic bags, with relevant history of the truck and engine, to:
Steve Keenan,
Application and Service Engineer-
Caterpillar of Australia.
Private Mailbag 4.
Tuilamarine. 3043.
Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
(1-Rework Procedure)Rework Procedure
1. Refer to attached parts book drawings.2. Obtain an ECM print-out from the Truck. Retain this print-out.3. Remove set of unit injectors. (Code 1290-010: refer p.109 of TRG for 3406E on highway truck engines;4. Drain and collect coolant.5. Remove and install set of unit injector sleeves (Code 1713-010: refer p. 111 of TRG).6. Replace injector body seals and sleeve seals. Return seals only as per parts disposition.7. Install set of unit injectors.8. Refill with coolant.9. Install set of unit injector sleeves.
Illustration 1.
Illustration 2.