Information injection-pump assembly
BOSCH
9 400 619 465
9400619465
ZEXEL
106873-7360
1068737360
Rating:
Service parts 106873-7360 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME093528
12.
Open Pre:MPa(Kqf/cm2)
15.
NOZZLE SET
Include in #1:
106873-7360
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 619 465
9400619465
ZEXEL
106873-7360
1068737360
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
131425-0220
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
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
1-2-7-3-
4-5-6-8
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.9
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
159
154.2
163.8
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.6+-0.5
Pump speed
r/min
415
415
415
Each cylinder's injection qty
mm3/st.
19
16.1
21.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.9)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
159
158
160
Basic
*
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.65
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
166.5
162.5
170.5
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-1.2
Boost pressure
kPa
6.7
5.4
8
Boost pressure
mmHg
50
40
60
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-1.
2)
Boost pressure
kPa
12.7
12.7
12.7
Boost pressure
mmHg
95
95
95
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)Boost compensator stroke: BCL
(4)Damper spring setting
----------
T1=AC77 BCL=1.2+-0.1mm
----------
----------
T1=AC77 BCL=1.2+-0.1mm
----------
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=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Viewed from feed pump side.
(2)Use the hole at R = aa
(3)Stopper bolt set position 'H'
----------
aa=37.5mm
----------
a=11.5deg+-5deg b=(39.5deg)+-3deg
----------
aa=37.5mm
----------
a=11.5deg+-5deg b=(39.5deg)+-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.)
(3)Normal engine position (Rack position corresponding to dd)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1(13.9)+1.65mm
----------
----------
N1=1100r/min Ra=R1(13.9)+1.65mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=4deg
----------
a=(50deg)
----------
aa=4deg
----------
a=(50deg)
Information:
North America Only
When a problem arises concerning the sale, operation or service of your engine, it will normally be handled by the dealer in your area. The service facility nearest you can be located twenty-four hours a day by calling the phone number below:In U.S. and Canada: 1 (800) 447-4986Your satisfaction is a primary concern to Caterpillar and its dealers. If you have a problem that has not been handled to your complete satisfaction, we suggest the steps that follow.Step One
Discuss your problem with a member of management from the dealership.Step Two
When it appears that your problem cannot be readily resolved at the dealer level without additional assistance, use the above telephone numbers and ask to talk to a Field Service Coordinator. Regular Monday through Friday business hours are from 8:00 a.m. to 4:30 p.m. Central Standard Time (CST).Step Three
If you are still not satisfied, present the engine matter in writing to:Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg. A
P.O. Box 600
Peoria, Illinois 61552-0600
When contacting the Manager, Customer Service, please keep in mind that ultimately your problem will likely be resolved at the dealership using their facilities, equipment, and personnel. Therefore, it is suggested that you follow the above steps in sequence when experiencing a problem.Outside North America
If a problem arises outside North America, and cannot be resolved at the dealer level, contact the appropriate Caterpillar subsidiary office.Central/South America (except Brazil)
Caterpillar Americas Co.
100 NE Adams Street
Peoria, Illinois 61629 U.S.A.
Phone: 309-675-5876
Fax: 309-675-5384
Brazil
Caterpillar Americas Co.
Edificio Brasil Interpart
Rua Guararapes, 2064 5.0 andar, cj.2
04561-004 - Sao Paulo-SP-Brazil
01.000-Sao Paulo-SP-Brazil
Phone: 011-536-3388
Fax: 011-505-1647
Far East (except Japan and Australia)
Caterpillar Far East Limited
28th Floor, Sun Hung Kai Centre
30 Harbour Road
G.P.O. Box 3069
Wanchai, Hong Kong
Cable Address: CATFAREAST HKG
Telex No: HX73305 CFEL
Phone: 5-8326333
Australia and New Zealand
Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Telex: AA30240
Cable: CATERPILLAR MELB
Phone: (03) 339-9333
Fax: (03) 335-3366
Japan
Caterpillar Mitsubishi Ltd.
3700, Tana, Sagamihara-shi
Kanagawa-ken, 229
Japan
Telex No: 2872-261CM HAJ
Cable Address: CATERBISHICO SAGAMIHARA
Phone: Sagamihara (0427) 62-1121
Fax: (0427) 62-8542
Europe, Africa, and Middle East
Caterpillar Overseas S.A./Power Systems
YA50 76, Route de Frontenex
P.O. Box 456
1211 Geneva 6
Switzerland
Cable Address: CATOVERSEA
Telex No.: 413323
Phone: (022) 849-4444
Telecopier: (022) 849-4984
Fax: (022) 849-4544
When a problem arises concerning the sale, operation or service of your engine, it will normally be handled by the dealer in your area. The service facility nearest you can be located twenty-four hours a day by calling the phone number below:In U.S. and Canada: 1 (800) 447-4986Your satisfaction is a primary concern to Caterpillar and its dealers. If you have a problem that has not been handled to your complete satisfaction, we suggest the steps that follow.Step One
Discuss your problem with a member of management from the dealership.Step Two
When it appears that your problem cannot be readily resolved at the dealer level without additional assistance, use the above telephone numbers and ask to talk to a Field Service Coordinator. Regular Monday through Friday business hours are from 8:00 a.m. to 4:30 p.m. Central Standard Time (CST).Step Three
If you are still not satisfied, present the engine matter in writing to:Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg. A
P.O. Box 600
Peoria, Illinois 61552-0600
When contacting the Manager, Customer Service, please keep in mind that ultimately your problem will likely be resolved at the dealership using their facilities, equipment, and personnel. Therefore, it is suggested that you follow the above steps in sequence when experiencing a problem.Outside North America
If a problem arises outside North America, and cannot be resolved at the dealer level, contact the appropriate Caterpillar subsidiary office.Central/South America (except Brazil)
Caterpillar Americas Co.
100 NE Adams Street
Peoria, Illinois 61629 U.S.A.
Phone: 309-675-5876
Fax: 309-675-5384
Brazil
Caterpillar Americas Co.
Edificio Brasil Interpart
Rua Guararapes, 2064 5.0 andar, cj.2
04561-004 - Sao Paulo-SP-Brazil
01.000-Sao Paulo-SP-Brazil
Phone: 011-536-3388
Fax: 011-505-1647
Far East (except Japan and Australia)
Caterpillar Far East Limited
28th Floor, Sun Hung Kai Centre
30 Harbour Road
G.P.O. Box 3069
Wanchai, Hong Kong
Cable Address: CATFAREAST HKG
Telex No: HX73305 CFEL
Phone: 5-8326333
Australia and New Zealand
Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Telex: AA30240
Cable: CATERPILLAR MELB
Phone: (03) 339-9333
Fax: (03) 335-3366
Japan
Caterpillar Mitsubishi Ltd.
3700, Tana, Sagamihara-shi
Kanagawa-ken, 229
Japan
Telex No: 2872-261CM HAJ
Cable Address: CATERBISHICO SAGAMIHARA
Phone: Sagamihara (0427) 62-1121
Fax: (0427) 62-8542
Europe, Africa, and Middle East
Caterpillar Overseas S.A./Power Systems
YA50 76, Route de Frontenex
P.O. Box 456
1211 Geneva 6
Switzerland
Cable Address: CATOVERSEA
Telex No.: 413323
Phone: (022) 849-4444
Telecopier: (022) 849-4984
Fax: (022) 849-4544