107691-0160 ZEXEL 9 400 618 872 BOSCH INJECTION-PUMP ASSEMBLY 9400618872 1076910160 16801z5570

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 872 9400618872

ZEXEL 107691-0160 1076910160

NISSAN-DIESEL 16801Z5570 16801z5570

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Cross reference number

BOSCH 9 400 618 872 9400618872

ZEXEL 107691-0160 1076910160

NISSAN-DIESEL 16801Z5570 16801z5570

Zexel num

Bosch num

Firm num

Name

107691-0160

9 400 618 872

16801Z5570 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6TA K

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Rack position (11.3)

PWM % 51.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 108 107 109

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 (6.7)

PWM % 25.6+-2. 8

Pump speed r/min 445 445 445

Average injection quantity mm3/st. 11 9.2 12.8

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

Governor adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.3

Governor adjustment_03

Pump speed r/min 1300

Advance angle deg. 4 3.7 4.3

Remarks
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

_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
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aa=20mm bb=1mm
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a=27deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=5.1+-0.03mm
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a=(20deg)

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.
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0000001301

A : Stopper pin B: Connector
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0000001401

C:Shim
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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.
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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.
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a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
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Information:

PARTS NEEDED
Qty
Part Number Description
2 1790133 FILM-AIR SHUTOFF
2 2898498 DAMPER AS
ACTION REQUIRED
Refer to the attached Rework Procedure.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 1.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR ADDING VIBRATION DAMPERS TO AIR SHUT OFFS
MODELS INVOLVED - CERTAIN 3500 DIESEL ENGINES
Dear Caterpillar Product Owner:
New vibration dampers need to be installed on the products listed. You will not be charged for the service performed. Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
It is VERY IMPORTANT that your Air Shut Offs be tested every 500 operating hours and the vibration dampers installed on the ASOs need to be inspected/serviced every 6000 operating hours. Please contact your Caterpillar Dealer for a copy of Caterpillar Special Instruction REHS3005, which details this procedure. A COPY OF THIS DOCUMENT SHOULD BE PLACED IN THE APPLICABLE Operating and Maintenance Manuals.
Please refer the dealer to their Service Letter dated 27Jul2006 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 27Jul2006 Service Letter
Rework Procedure
1. Remove existing plug from bottom of each Air Shut Off (ASO) housing, Image 1.1.1
Image1.1.1
2. Install new Vibration Damper P/N 289-8498 into the hole as shown in image 1.2.1, insuring that the threads are coated with Thread lock P/N 9S-3263 or 4C-4030 and torque the damper to 16 (+/- 2)Nm.
Image1.2.1
3. Install information labels over existing labels on the electrically actuated ASO solenoids as shown in image 1.3.1 or on hydraulically actuated ASO valve covers as shown in image 1.3.2.
Labels in languages other than English are available under the following Part Numbers:
-Arabic 297-2613
-French 297-2614
-German 297-2615
-Spanish 297-2616
-Portuguese 297-2617
-Russian 297-2618
Image1.3.1
Image1.3.2