Information injection-pump assembly
BOSCH
9 400 618 661
9400618661
ZEXEL
106971-0910
1069710910
NISSAN-DIESEL
1671397168
1671397168
Rating:
Cross reference number
BOSCH
9 400 618 661
9400618661
ZEXEL
106971-0910
1069710910
NISSAN-DIESEL
1671397168
1671397168
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
105780-8140
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
10-9-4-3
-6-5-8-7
-2-1
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 10-9 deg. 45 44.5 45.5
Cal 10-9 deg. 45 44.5 45.5
Difference between angles 2
Cal 10-4 deg. 72 71.5 72.5
Cal 10-4 deg. 72 71.5 72.5
Difference between angles 3
Cal 10-3 deg. 117 116.5 117.5
Cal 10-3 deg. 117 116.5 117.5
Difference between angles 4
Cal 10-6 deg. 144 143.5 144.5
Cal 10-6 deg. 144 143.5 144.5
Difference between angles 5
Cal 10-5 deg. 189 188.5 189.5
Cal 10-5 deg. 189 188.5 189.5
Difference between angles 6
Cal 10-8 deg. 216 215.5 216.5
Cal 10-8 deg. 216 215.5 216.5
Difference between angles 7
Cal 10-7 deg. 261 260.5 261.5
Cal 10-7 deg. 261 260.5 261.5
Difference between angles 8
Cal 10-2 deg. 288 287.5 288.5
Cal 10-2 deg. 288 287.5 288.5
Difference between angles 9
Cal 10-1 deg. 333 332.5 333.5
Cal 10-1 deg. 333 332.5 333.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.8
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
192.2
190.2
194.2
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
3.6+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
17.8
15.8
19.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
11.8+-0.
1
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
215
205
225
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
(700)
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1150
Advance angle
deg.
3
2.5
3.5
Timer adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
3.5
3.5
3.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Set idle sub-spring
(4)Damper spring setting: DL
(5)Main spring setting
----------
K=11 RAL=11.8+-0.1mm DL=3.6-0.5-0.7mm
----------
----------
K=11 RAL=11.8+-0.1mm DL=3.6-0.5-0.7mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=11deg+-5deg b=32deg+-5deg c=32deg+-3deg
----------
----------
a=11deg+-5deg b=32deg+-5deg c=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=(21deg)+-5deg b=36deg+-5deg
----------
----------
a=(21deg)+-5deg b=36deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of the gear's standard threaded installation hole at the start of injection for the No. 10 cylinder.
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Governor Actuator Mounting Replacement:
Removal Of The Previous Assembly
1. Disconnect linkage from cylinder and fuel pump, disassemble bracket from fuel pump lever.2. Remove cylinder from mounting plate, twist out rod end from cylinder.3. Remove mounting plate.Installing Of The New Linkage
1. Install 1433909, 8T4908, 8T4224, 9X6032, 8T4121 Linkage Assembly to engine block.2. Screw in U-joint of 1233885 Cylinder Rod as close as possible, tighten with 1426000 Nut, assemble cylinder with 8T1160 Bolts to the hinge.3. Assemble lever with washer and lock nut (1392085, 8T0389, 1392082, 8T4121), check free movement.4. Disconnect electrical connector from cylinder, turn on ignition, so that cylinder extends.5. Ensure pre-adjustment (overlapping of 1 mm) of U-joint and lever using the 8T4195 Stop Screw; tighten screw with nut (8T4133); See Illustration 2.6. Connect electrical connector to the cylinder and link up rod and lever with the 1233884 Pin.
Illustration 2Calibration
All adjustments have to be done with machine / engine at operating temperature
1. Start the engine.2. Plug-in PDT (portable diagnostic tool), choose menu "PROC" number 5 "ENGINE RPM" and number 6 "RPM DIFFERENCE". High And Low Idle Adjustment At Injection Pump:
1. Actuate the lever of the fuel injection pump by hand and adjust high and low idle by turning the corresponding stop screw at the fuel injection pump. If necessary fix the lever in the high idle position by use of a light spring to make adjustment easier:Set low idle to: 750 Rpm -20/+0 RpmSet high idle to : 2400 Rpm -0/+20 Rpm2. Make sure that when this is set a 1 mm spacer is fitted between the throttle lever and the high idle adjustment screw (see Illustration 3).3. Secure stop screw with locking nut. Seal setting with lockwire and lead seal, use your CAT dealer identification pliers.4. Disconnect electrical connector from the actuator (actuator piston extends completely).5. Stop the engine.6. Assemble and connect the 1413978 or 1397394, 9X8256, 1400277, 6V7743, 5C2890, 1107299, 1396903 Adjustable Rod, use the center hole at the fuel injection pump lever. Make sure that there is no contact between the fuel injection pump lever and the stop screw at high idle position.7. Start the engine.8. Adjust high idle setting with the rod:M312: high idle 2150 Rpm -0/+20 Rpm.M315: high idle 2400 Rpm -0/+20 Rpm.9. Secure the rod with the nuts at the ball joints.10. Mark the lock nut positions at the ball joints with a paint dot or using a felt-tip pen.11. Connect the electrical connector to the actuator.
Illustration 3Calibration/Adjustment Of The Engine
1. Press "F 1" key at the PDT for calibration.2. Choose item number 2 "CALIBRATION".3. Choose item number 1 "SPEED DIAL CAL".4. "MIN POSITION" setting, turn potentiometer on the panel until you receive the minimum voltage shown in the screen, press "ENTER".5. "MAX POSITION" setting, turn potentiometer until you receive maximum voltage shown in the screen, press "ENTER".6. You automatically get back into the previous menu, now choose number 2 "SPEED CAL".7. Change the low idle setting to 1020 Rpm by using the "UP- "or "DOWN-ARROW" keys at the PDT, when finished,
Removal Of The Previous Assembly
1. Disconnect linkage from cylinder and fuel pump, disassemble bracket from fuel pump lever.2. Remove cylinder from mounting plate, twist out rod end from cylinder.3. Remove mounting plate.Installing Of The New Linkage
1. Install 1433909, 8T4908, 8T4224, 9X6032, 8T4121 Linkage Assembly to engine block.2. Screw in U-joint of 1233885 Cylinder Rod as close as possible, tighten with 1426000 Nut, assemble cylinder with 8T1160 Bolts to the hinge.3. Assemble lever with washer and lock nut (1392085, 8T0389, 1392082, 8T4121), check free movement.4. Disconnect electrical connector from cylinder, turn on ignition, so that cylinder extends.5. Ensure pre-adjustment (overlapping of 1 mm) of U-joint and lever using the 8T4195 Stop Screw; tighten screw with nut (8T4133); See Illustration 2.6. Connect electrical connector to the cylinder and link up rod and lever with the 1233884 Pin.
Illustration 2Calibration
All adjustments have to be done with machine / engine at operating temperature
1. Start the engine.2. Plug-in PDT (portable diagnostic tool), choose menu "PROC" number 5 "ENGINE RPM" and number 6 "RPM DIFFERENCE". High And Low Idle Adjustment At Injection Pump:
1. Actuate the lever of the fuel injection pump by hand and adjust high and low idle by turning the corresponding stop screw at the fuel injection pump. If necessary fix the lever in the high idle position by use of a light spring to make adjustment easier:Set low idle to: 750 Rpm -20/+0 RpmSet high idle to : 2400 Rpm -0/+20 Rpm2. Make sure that when this is set a 1 mm spacer is fitted between the throttle lever and the high idle adjustment screw (see Illustration 3).3. Secure stop screw with locking nut. Seal setting with lockwire and lead seal, use your CAT dealer identification pliers.4. Disconnect electrical connector from the actuator (actuator piston extends completely).5. Stop the engine.6. Assemble and connect the 1413978 or 1397394, 9X8256, 1400277, 6V7743, 5C2890, 1107299, 1396903 Adjustable Rod, use the center hole at the fuel injection pump lever. Make sure that there is no contact between the fuel injection pump lever and the stop screw at high idle position.7. Start the engine.8. Adjust high idle setting with the rod:M312: high idle 2150 Rpm -0/+20 Rpm.M315: high idle 2400 Rpm -0/+20 Rpm.9. Secure the rod with the nuts at the ball joints.10. Mark the lock nut positions at the ball joints with a paint dot or using a felt-tip pen.11. Connect the electrical connector to the actuator.
Illustration 3Calibration/Adjustment Of The Engine
1. Press "F 1" key at the PDT for calibration.2. Choose item number 2 "CALIBRATION".3. Choose item number 1 "SPEED DIAL CAL".4. "MIN POSITION" setting, turn potentiometer on the panel until you receive the minimum voltage shown in the screen, press "ENTER".5. "MAX POSITION" setting, turn potentiometer until you receive maximum voltage shown in the screen, press "ENTER".6. You automatically get back into the previous menu, now choose number 2 "SPEED CAL".7. Change the low idle setting to 1020 Rpm by using the "UP- "or "DOWN-ARROW" keys at the PDT, when finished,