Information injection-pump assembly
BOSCH
9 400 618 859
9400618859
ZEXEL
107691-0000
1076910000
NISSAN-DIESEL
16801Z5511
16801z5511
Rating:
Service parts 107691-0000 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
16600-Z5701
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/20.6{210}
15.
NOZZLE SET
Include in #1:
107691-0000
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 859
9400618859
ZEXEL
107691-0000
1076910000
NISSAN-DIESEL
16801Z5511
16801z5511
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
134424-4120
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
RED4 control unit part number
407915-0
590
RED4 rack sensor specifications
mm
19
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
14
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
1-4-2-6-
3-5
Pre-stroke
mm
5.1
5.07
5.13
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Rack position
(10.5)
PWM
%
47.4
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
90.5
89.5
91.5
Max. variation between cylinders
%
0
-4
4
Basic
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Injection quantity adjustment_02
Rack position
(6.3)
PWM
%
23.4+-2.
8
Pump speed
r/min
430
430
430
Average injection quantity
mm3/st.
9
7.2
10.8
Max. variation between cylinders
%
0
-10
10
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
1200--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
1150
Advance angle
deg.
0.3
Governor adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
4
3.7
4.3
Remarks
Finish
Finish
0000001201
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.1
5.07
5.13
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
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 timer's threaded hole at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=5.1+-0.03mm
----------
a=(70deg)
----------
aa=5.1+-0.03mm
----------
a=(70deg)
Stop lever angle
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001301
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001401
C:Shim
----------
----------
----------
----------
0000001501
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000001701
(PWM) Pulse width modulation (%)
(R) Rack position (mm)
Rack sensor output characteristics
1. Rack limit adjustment
(1)Measure the rack position R2 for PWM a2%.
(2)Confirm that it is within the range R2 = 15+-1 mm.
(3)Measure the rack position R1 at PWM a %.
(4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm.
2. Check the limp home operation.
(1)Move the switch box's limp home switch to the limp home side.
(2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table.
3. Check the pull down operation.
(1)Confirm that the rack position is 19 mm at PWM B%.
(2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5% B=95%
----------
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5% B=95%
----------
Information:
Installation Procedure
Illustration 1 g06124125
Remove plate (1) and discard. Save the hardware and hook assembly (2) for reuse.
Illustration 2 g06124137
(3) 5I-3822 Plate
Weld plate (3) in the location specified in Illustration 2.
Illustration 3 g06124150
Remove two hoses (4).
Illustration 4 g06124157
(5) 467-9635 Hose
(6) 428-8808 Hose Clamp
(7) 418-2057 Hose
(8) 467-9634 Hose
(9) 5P-4924 Elbow
(10) 6V-3250 O-Ring Seal
(11) 424-1209 Tank
Install hose (7) and two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install one end of hose (5) on the coolant tube and the other on tank (11). Secure the hose using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install elbow (9) and O-ring (10) onto tank (11). Tighten the elbow to 28 4 N m (21 3 lb ft).
Install hose (8) as shown using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in). Ensure the hoses connected to the tank are in parallel as shown in view D-D.
Illustration 5 g06124173
(12) 326-4516 Cable Tie
(13) 454-4235 Plate
Secure the hoses as shown using two cable ties (12) and plate (13).
Illustration 6 g06124183
(14) 511-8273 Sheet As
Install sheet (14) and hook assembly (2) using the saved hardware.
Illustration 7 g06124176
(11) 424-1209 Tank
(15) 467-9640 Plate As
(16) 8T-4136 Bolt
(17) 8T-4121 Hard Washer
(18) 8T-4189 Bolt
(19) 8T-4224 Hard Washer
Install plate assembly (15) using three bolts (16) and three washers (17).
Mount tank (11) onto plate (15) using two bolts (18) and two washers (19).
Install new machine, engine, and after treatment software. The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). SIS web only displays the latest available flash file.
Illustration 8 g06123932
Update the DES threshold to 525 degrees C using Cat® Electronic Technician (Cat ET). A factory password is required to change the value. A factory password can be obtained after inputting your Corporate Web Security (CWS) identification.
Illustration 1 g06124125
Remove plate (1) and discard. Save the hardware and hook assembly (2) for reuse.
Illustration 2 g06124137
(3) 5I-3822 Plate
Weld plate (3) in the location specified in Illustration 2.
Illustration 3 g06124150
Remove two hoses (4).
Illustration 4 g06124157
(5) 467-9635 Hose
(6) 428-8808 Hose Clamp
(7) 418-2057 Hose
(8) 467-9634 Hose
(9) 5P-4924 Elbow
(10) 6V-3250 O-Ring Seal
(11) 424-1209 Tank
Install hose (7) and two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install one end of hose (5) on the coolant tube and the other on tank (11). Secure the hose using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in).
Install elbow (9) and O-ring (10) onto tank (11). Tighten the elbow to 28 4 N m (21 3 lb ft).
Install hose (8) as shown using two hose clamps (6). Slowly tighten the clamps to 6.6 0.2 N m (58 1.8 lb in). Ensure the hoses connected to the tank are in parallel as shown in view D-D.
Illustration 5 g06124173
(12) 326-4516 Cable Tie
(13) 454-4235 Plate
Secure the hoses as shown using two cable ties (12) and plate (13).
Illustration 6 g06124183
(14) 511-8273 Sheet As
Install sheet (14) and hook assembly (2) using the saved hardware.
Illustration 7 g06124176
(11) 424-1209 Tank
(15) 467-9640 Plate As
(16) 8T-4136 Bolt
(17) 8T-4121 Hard Washer
(18) 8T-4189 Bolt
(19) 8T-4224 Hard Washer
Install plate assembly (15) using three bolts (16) and three washers (17).
Mount tank (11) onto plate (15) using two bolts (18) and two washers (19).
Install new machine, engine, and after treatment software. The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). SIS web only displays the latest available flash file.
Illustration 8 g06123932
Update the DES threshold to 525 degrees C using Cat® Electronic Technician (Cat ET). A factory password is required to change the value. A factory password can be obtained after inputting your Corporate Web Security (CWS) identification.