107691-0203 ZEXEL 9 400 611 800 BOSCH INJECTION-PUMP ASSEMBLY 9400611800 1076910203 16801z5615

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 800 9400611800

ZEXEL 107691-0203 1076910203

NISSAN-DIESEL 16801Z5615 16801z5615

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Buy INJECTION-PUMP ASSEMBLY 107691-0203 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-0203 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1460

3. GOVERNOR 105961-0071

4. SUPPLY PUMP 105237-5460

5. AUTOM. ADVANCE MECHANIS 105681-2600

6. COUPLING PLATE 105664-2551

7. COUPLING PLATE

8. _ 159645-2020

9. _

10. NOZZLE AND HOLDER ASSY 105118-7850

11. Nozzle and Holder 16600-Z5714

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/19.6{200}

13. NOZZLE-HOLDER 105048-4360

14. NOZZLE

15. NOZZLE SET 105019-1720

Include in #1:

107691-0203 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 800 9400611800

ZEXEL 107691-0203 1076910203

NISSAN-DIESEL 16801Z5615 16801z5615

Zexel num

Bosch num

Firm num

Name

107691-0203

9 400 611 800

16801Z5615 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6TB K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

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
----------
aa=1mm bb=20mm
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a=20deg+-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)-
----------
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.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
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Information:

This Revised Service Letter replaces the 20Nov2008 Service Letter. Changes have been made to Parts Needed Description.
TERMINATION DATE
30Nov2010
PROBLEM
The existing governor linkage can separate at the riveted joint on certain C1.6 engines. If the existing governor linkage fails, it can result in loss of engine speed governing.
AFFECTED PRODUCT
Model Identification Number
C1.6 C1M00596-00703, 740-883
PARTS NEEDED
Qty
Part Number Description
1 2152619 GASKET
1 2908469 LEVER AS
1 2952235 GASKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 9% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Gain access to engine front cover and fuel pump. Replace the existing governor linkage using the following steps.
Refer to service manual module RENR2424.
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-2000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Refer to service manual module RENR2424.
1. Remove fuel injection pump. Refer to SMCS 1251-011 (Fuel Injection Pump-Remove).
2. Remove crankshaft pulley. Refer to SMCS 1205-010 (Crankshaft Pulley-Remove and Install).
3. Remove engine front cover. Refer to SMCS 1151-011 (Housing (Front) Remove).
4. Remove fuel injection pump linkage from housing. Refer to SMCS 1151-015 (Housing (Front)-Disassemble).
5. Install new 290-8469 fuel injection pump linkage. Refer to 'Installation of fuel injection pump linkage' within SMCS 1151-016 (Housing (Front)-Assemble).
6. Install engine front cover with new gasket. Refer to SMCS 1151-012 (Housing (Front)-Install).
7. Install crankshaft pulley. Refer to SMCS 1205-010 (Crankshaft Pulley - Remove and Install).
8. Install fuel injection pump. Refer to SMCS 1251-012 (Fuel Injection Pump - Install).
9. Run engine to ensure correct operation. Check for any signs of leaks.
10. Check low and high idle, and reset appropriately.
11. Refit any machine parts that were removed to gain access to engine front cover and fuel pump.