Information injection-pump assembly
BOSCH
9 400 611 553
9400611553
ZEXEL
106971-5193
1069715193
NISSAN-DIESEL
1680197063
1680197063
Rating:
Service parts 106971-5193 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:
106971-5193
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 553
9400611553
ZEXEL
106971-5193
1069715193
NISSAN-DIESEL
1680197063
1680197063
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
10-9-4-3
-6-5-8-7
-2-1
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 10-9 deg. 45 44.75 45.25
Cal 10-9 deg. 45 44.75 45.25
Difference between angles 2
Cal 10-4 deg. 72 71.75 72.25
Cal 10-4 deg. 72 71.75 72.25
Difference between angles 3
Cal 10-3 deg. 117 116.75 117.25
Cal 10-3 deg. 117 116.75 117.25
Difference between angles 4
Cal 10-6 deg. 144 143.75 144.25
Cal 10-6 deg. 144 143.75 144.25
Difference between angles 5
Cal 10-5 deg. 189 188.75 189.25
Cal 10-5 deg. 189 188.75 189.25
Difference between angles 6
Cal 10-8 deg. 216 215.75 216.25
Cal 10-8 deg. 216 215.75 216.25
Difference between angles 7
Cal 10-7 deg. 261 260.75 261.25
Cal 10-7 deg. 261 260.75 261.25
Difference between angles 8
Cal 10-2 deg. 288 287.75 288.25
Cal 10-2 deg. 288 287.75 288.25
Difference between angles 9
Cal 10-1 deg. 333 332.75 333.25
Cal 10-1 deg. 333 332.75 333.25
Injection quantity adjustment
Rack position
(13.4)
Vist
V
1.84
1.84
1.84
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
128.5
126.5
130.5
Max. variation between cylinders
%
0
-4
4
Basic
*
Injection quantity adjustment_02
Rack position
(8.8)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
370
370
370
Average injection quantity
mm3/st.
16
14
18
Max. variation between cylinders
%
0
-10
10
Test data Ex:
Governor 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 N4=800r/min C4=(9deg) t1=1.7--sec. t2=1.7--sec.
----------
N1=400r/min N2=1000++r/min N3=- C1=9+-0.3deg C2=3.5++deg C3=- P1=0kPa(0kgf/cm2) P2=294kPa(3kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
----------
L=1-0.2mm N4=800r/min C4=(9deg) t1=1.7--sec. t2=1.7--sec.
----------
N1=400r/min N2=1000++r/min N3=- C1=9+-0.3deg C2=3.5++deg C3=- P1=0kPa(0kgf/cm2) P2=294kPa(3kgf/cm2) P3=392kPa(4kgf/cm2) R01=0/4load R02=4/4load R03=4/4load
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 start of injection for the No. 10 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.
----------
----------
----------
----------
Information:
November 10, 2003
U-307
A-211
D-227
O-256
TT-24
TM-7
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN REMAN FUEL INJECTORS FROM DEALER PART STOCK
7750 PI70071
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
February 29, 2004PROBLEM
Certain fuel injectors need to be removed fromdealer part stock. A number of fuel injectors were built with a Valve OpeningPressure (VOP) spacer that missed a hardening operation. This non-hardenedspacer allows premature wear, causing several operational problems whichmay include: engine misfire, low power, white smoke, and engine would notstart.ACTION REQUIRED
Only remove engine injectors within the suspectdate code range from your parts supply.
In order to perform this inspection, injectorsmust be removed from the packaging.
Repackage all injectors.
Illustration 1 (3406E, C15) Illustration 2 (C10, C12)SERVICE CLAIM ALLOWANCES
Submit one claim for all 0R4667, 0R4893, 0R4894,0R4895, 0R9256, 0R9257, 0R9258, 0R9259, 0R9803, 0R4986, 0R4987, 0R4988,0R7549, 0R8773, 0R8780, and 0R9530 removed from parts stock. Remove onlythose injectors from the suspect serial number range listed below. 0R4667, 0R4893, 0R4894, 0R4895, 0R9256,0R9257, 0R9258, 0R9259, and 0R9803 3406E and C15 injectors should be removedif the serial number is between 318224-371662. 0R4986, 0R4987, 0R4988, 0R7549, 0R8773,0R8780, and 0R9530 C10 and C12 injectors should be removed if the serialnumber is between 34768-47935.PARTS DISPOSITION
These remanufactured parts need to be returnedwith dealer normal core returns in order to allow for core deposit refund.
U-307
A-211
D-227
O-256
TT-24
TM-7
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN REMAN FUEL INJECTORS FROM DEALER PART STOCK
7750 PI70071
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
February 29, 2004PROBLEM
Certain fuel injectors need to be removed fromdealer part stock. A number of fuel injectors were built with a Valve OpeningPressure (VOP) spacer that missed a hardening operation. This non-hardenedspacer allows premature wear, causing several operational problems whichmay include: engine misfire, low power, white smoke, and engine would notstart.ACTION REQUIRED
Only remove engine injectors within the suspectdate code range from your parts supply.
In order to perform this inspection, injectorsmust be removed from the packaging.
Repackage all injectors.
Illustration 1 (3406E, C15) Illustration 2 (C10, C12)SERVICE CLAIM ALLOWANCES
Submit one claim for all 0R4667, 0R4893, 0R4894,0R4895, 0R9256, 0R9257, 0R9258, 0R9259, 0R9803, 0R4986, 0R4987, 0R4988,0R7549, 0R8773, 0R8780, and 0R9530 removed from parts stock. Remove onlythose injectors from the suspect serial number range listed below. 0R4667, 0R4893, 0R4894, 0R4895, 0R9256,0R9257, 0R9258, 0R9259, and 0R9803 3406E and C15 injectors should be removedif the serial number is between 318224-371662. 0R4986, 0R4987, 0R4988, 0R7549, 0R8773,0R8780, and 0R9530 C10 and C12 injectors should be removed if the serialnumber is between 34768-47935.PARTS DISPOSITION
These remanufactured parts need to be returnedwith dealer normal core returns in order to allow for core deposit refund.