Information injection-pump assembly
BOSCH
9 400 619 680
9400619680
ZEXEL
101495-3171
1014953171
Rating:
Service parts 101495-3171 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 619 680
9400619680
ZEXEL
101495-3171
1014953171
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
1-2-4-3
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.3
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
66.1
65.1
67.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.6+-0.5
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
10.5
9.5
11.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
15+0.2
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65.5
55.5
75.5
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)The torque control spring must does not have a set force.
----------
K=12 RAL=15+0.2mm
----------
----------
K=12 RAL=15+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Use the hole at R = aa
----------
aa=60mm
----------
a=35deg+-5deg b=21deg+-5deg c=32deg+-3deg
----------
aa=60mm
----------
a=35deg+-5deg b=21deg+-5deg c=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=1deg+-5deg b=53deg+-5deg
----------
----------
a=1deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
Introduction
The following Special Instruction must be used to package a DPF for a core return.
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Note: Whenever the filter is replaced the engine ash model must be reset. Refer to the section below for information on how to reset the ash model.Reset the Engine Ash Model
The engine ash model must be reset whenever the filter is cleaned or replaced. Reseting the ash model places the DPF volume back to the "Clean State". The resetting will allow the regeneration of the DPF to function properly.
Connect to Cat® Electronic Technician (Cat® ET).
Illustration 1 g03345441
Connect to "Engine #1 Aftertreatment Controller".
Illustration 2 g03345627
Select "Service" from the top menu and select "Service Procedures".
Illustration 3 g03345631
From the "Service Procedures" menu, select "DPF Ash Service".
Select "Start".
Illustration 4 g03345633
Select "Ash Service Reset" to start the reset procedure.
Illustration 5 g03345638
You must read the warning and select "Agree" in order to continue.
Illustration 6 g03345643
Choose the correct replacement type of DPF in the menu that appears. The types of replacements for the DPF are the following:
"Field Cleaned" A DPF that has been cleaned and reapplied.
"New" A new DPF replacement
"Remanufactured" A remanufactured DPF replacement.
Illustration 7 g03345648
Illustration 8 g03345650
One the reset is completed, a log of the reset is captured and visible as a new row of information in the DPF Ash Service screen. Resetting the engine ash model does not reset the soot level.
Perform a "Manual DPF Regeneration" with Cat® ET to reset the soot level.Packaging Instructions
Note: The replacement DPF will be packaged with a bag and zip-tie that are used to repackage the DPF that has been removed.
Place the DPF being returned in the enclosed bag and seal the bag with the enclosed zip-tie.
Place the enclosed warning label on the outside of the bag.
Place half of the foam insert on the bottom of the original shipping box with the cut out in the insert facing up.
Place the DPF into the box fitting the DPF into the cut out in the insert.
Place the second half of the foam insert on to of the DPF with the cut out in the insert facing down onto the DPF.
Seal the box with packing tape.Note: If the package weighs over 16 kg (35 lb), additional tape or banding might be required.
Label the package for return shipment.
The following Special Instruction must be used to package a DPF for a core return.
Wear goggles, gloves, protective clothing, and a National Institute for Occupational Safety and Health (NIOSH) approved P95 or N95 half-face respirator when handling a used Diesel Particulate Filter or Catalytic Converter Muffler. Failure to do so could result in personal injury.
Note: Whenever the filter is replaced the engine ash model must be reset. Refer to the section below for information on how to reset the ash model.Reset the Engine Ash Model
The engine ash model must be reset whenever the filter is cleaned or replaced. Reseting the ash model places the DPF volume back to the "Clean State". The resetting will allow the regeneration of the DPF to function properly.
Connect to Cat® Electronic Technician (Cat® ET).
Illustration 1 g03345441
Connect to "Engine #1 Aftertreatment Controller".
Illustration 2 g03345627
Select "Service" from the top menu and select "Service Procedures".
Illustration 3 g03345631
From the "Service Procedures" menu, select "DPF Ash Service".
Select "Start".
Illustration 4 g03345633
Select "Ash Service Reset" to start the reset procedure.
Illustration 5 g03345638
You must read the warning and select "Agree" in order to continue.
Illustration 6 g03345643
Choose the correct replacement type of DPF in the menu that appears. The types of replacements for the DPF are the following:
"Field Cleaned" A DPF that has been cleaned and reapplied.
"New" A new DPF replacement
"Remanufactured" A remanufactured DPF replacement.
Illustration 7 g03345648
Illustration 8 g03345650
One the reset is completed, a log of the reset is captured and visible as a new row of information in the DPF Ash Service screen. Resetting the engine ash model does not reset the soot level.
Perform a "Manual DPF Regeneration" with Cat® ET to reset the soot level.Packaging Instructions
Note: The replacement DPF will be packaged with a bag and zip-tie that are used to repackage the DPF that has been removed.
Place the DPF being returned in the enclosed bag and seal the bag with the enclosed zip-tie.
Place the enclosed warning label on the outside of the bag.
Place half of the foam insert on the bottom of the original shipping box with the cut out in the insert facing up.
Place the DPF into the box fitting the DPF into the cut out in the insert.
Place the second half of the foam insert on to of the DPF with the cut out in the insert facing down onto the DPF.
Seal the box with packing tape.Note: If the package weighs over 16 kg (35 lb), additional tape or banding might be required.
Label the package for return shipment.