Information injection-pump assembly
ZEXEL
106861-0690
1068610690
NISSAN-DIESEL
1670097560
1670097560
Rating:
Service parts 106861-0690 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-97012
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
106861-0690
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106861-0690
1068610690
NISSAN-DIESEL
1670097560
1670097560
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 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
1-8-7-5-
4-3-6-2
Pre-stroke
mm
3.65
3.6
3.7
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5
Cal 1-8 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5
Cal 1-5 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5
Cal 1-3 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5
Cyl.1-2 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
109
108
110
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
11.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
107
104
110
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
11.5
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
112
108
116
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
5.6+-0.5
Pump speed
r/min
235
235
235
Average injection quantity
mm3/st.
18.6
16.6
20.6
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Timer adjustment
Pump speed
r/min
600
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
1
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
1.9
1.4
2.4
Timer adjustment_04
Pump speed
r/min
1250+-25
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)After completing adjustment of the broken line, set the lever at the unbroken line position.
(2)Beginning of damper spring operation: DL
(3)Rack limit using stop lever
----------
DL=5.1-0.5mm
----------
----------
DL=5.1-0.5mm
----------
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=13deg+-5deg b=23deg+-3deg
----------
----------
a=13deg+-5deg b=23deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=14deg+-5deg b=32deg+-3deg
----------
----------
a=14deg+-5deg b=32deg+-3deg
Information:
Remove the 345-2985 Ether Nozzles (Atomizers) or the plug in the hole in each intake manifold. Install the more robust 423-4336 Ether Nozzles (Atomizers) and related parts.
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all engines reworked in dealer parts stock. The parts listed in the Parts Needed will be allowed for each engine that is reworked. 1 hour labor will be allowed for each engine that is reworked. Include the engine serial numbers and arrangement numbers in the service claim story.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-21000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-21000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 1.0-hour job for Group 2
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Group Number 1
1. Remove the existing ether nozzles or plugs from the left and right intake manifolds.
2. Install the components identified in Image 1.1.1. Apply thread sealant (Loctite 536) to the threads of the 423-4336 Ether Nozzles before tightening (9 +/- 2 Nm) them into the intake manifolds.
3. Check to ensure that the ether control parameter is programmed to "Enabled" by using Cat ET.
Image1.1.1
Group Number 2
1. Remove the existing ether nozzles or plugs from the left and right intake manifolds.
2. Install the components identified in Image 2.1.1 on the front right side of the engine. Apply thread sealant (Loctite 536) to the threads of the 423-4336 Ether Nozzles before tightening (9 +/- 2 Nm) it into the intake manifold.
Image2.1.1
3. Install the components identified in Image 2.2.1 on the front left side of the engine. Apply thread sealant (Loctite 536) to the threads of the 423-4336 Ether Nozzles before tightening (9 +/- 2 Nm) it into the intake manifold.
4. Check to ensure that the ether control parameter is programmed to "Enabled" by using Cat ET.
Image2.2.1