Information injection-pump assembly
BOSCH
9 400 610 573
9400610573
ZEXEL
101602-2782
1016022782
Rating:
Service parts 101602-2782 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1830A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 573
9400610573
ZEXEL
101602-2782
1016022782
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
EF851/9A
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
Overflow valve
131424-8220
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-4-2-6-
3-5
Pre-stroke
mm
4
3.97
4.03
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
Adjusting point
A
Rack position
8.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
102
100
104
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.4
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
99.5
93.5
105.5
Max. variation between cylinders
%
0
-10
10
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
5.7+-0.5
Pump speed
r/min
410
410
410
Average injection quantity
mm3/st.
10
9
11
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_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
135
135
145
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
----------
K=8
----------
----------
K=8
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Stopper bolt setting
(2)Set the pump speed at aa
(3)Set the stopper bolt at delivery (idle side).
(4)Set the pump speed at bb.
----------
aa=930r/min bb=780r/min
----------
a=5deg+-5deg b=21deg+-5deg c=35deg+-3deg d=6deg+-5deg
----------
aa=930r/min bb=780r/min
----------
a=5deg+-5deg b=21deg+-5deg c=35deg+-3deg d=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position aa or less, pump speed bb
----------
aa=5mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
----------
aa=5mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(55deg)
----------
----------
a=(55deg)
Information:
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.DEF injectors are being replaced in the field and returned to Caterpillar for testing. Results of the testing are finding a large portion of the returned DEF injectors are found to be fault not repeated.This form is to be used and filled out in any case that a DEF injector is being replaced.The DEF injector troubleshooting return form needs to be completed and included within failed part returns documenting what was found that led to DEF injector replacement. Attach the photos of DEF injector tip and mount area along with a Product Status Report to the SIMS claim.References
Table 1
Engine Publication Type Media Number
C7.1 Troubleshooting UENR0668
Testing and Adjusting UENR4467
Disassembly and Assembly UENR4468
C9.3 Troubleshooting UENR0978
Testing and Adjusting UENR3402
Disassembly and Assembly UENR0130
C13 Troubleshooting UENR0955
Testing and Adjusting UENR4302
Disassembly and Assembly UENR0131
C15/C18 Troubleshooting UENR0955
Testing and Adjusting UENR3351
Disassembly and Assembly UENR0132 Procedure
What code are you troubleshooting? __________
Follow the correct troubleshooting procedure. Reference Table 1 for correct media number to use.
When troubleshooting procedure requests the DEF quality check, DEF injector resistance measurement, or Dosing Accuracy Test, document those results in Tables 2, 3, and 4.Tables
Table 2
DEF Quality Results
Step Instruction Completed (Yes/No) Result Comments Units
1 Follow the Testing and Adjusting procedure for "Diesel Exhaust Fluid Quality - Test"
2 DEF Contamination Test Pass / Fail
3 DEF Concentration Test % at 20° C (68° F)
Illustration 1 g06175415
Table 3
Injector Resistance Measurement
Step Instruction Completed (Yes/No) Result Comments Units
1 Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
2 Disconnect the DEF injectors from the applicable harness.
3 Inspect the connector for damage and debris.
4 Measure the temperature of the injector (aluminum body). C
5 Connect two 398-4987 Probes to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector. Reference Illustration 1 for example.
6 Measure the resistance of the DEF injector. Ohms
Table 4
Dosing Accuracy Test
Step Instruction Completed (Yes/No) Result Comments Units
1 Follow the Testing and Adjusting procedure for "Aftertreatment SCR System Dosing - Test"
2 Remove the injector from the DPF outlet.
3 Take a photograph of the DEF injector mount on the DPF outlet and the tip of the DEF injector.
4 Install the injector on the beaker.
5 Run the DEF System Dosing Accuracy test through Cat® Electronic Technician (ET).
6 Use the beaker to measure the amount of fluid from the dosing test. ml
7 Repeat the test to verify consistency. ml
8 Install the injector back onto the DPF outlet.
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.DEF injectors are being replaced in the field and returned to Caterpillar for testing. Results of the testing are finding a large portion of the returned DEF injectors are found to be fault not repeated.This form is to be used and filled out in any case that a DEF injector is being replaced.The DEF injector troubleshooting return form needs to be completed and included within failed part returns documenting what was found that led to DEF injector replacement. Attach the photos of DEF injector tip and mount area along with a Product Status Report to the SIMS claim.References
Table 1
Engine Publication Type Media Number
C7.1 Troubleshooting UENR0668
Testing and Adjusting UENR4467
Disassembly and Assembly UENR4468
C9.3 Troubleshooting UENR0978
Testing and Adjusting UENR3402
Disassembly and Assembly UENR0130
C13 Troubleshooting UENR0955
Testing and Adjusting UENR4302
Disassembly and Assembly UENR0131
C15/C18 Troubleshooting UENR0955
Testing and Adjusting UENR3351
Disassembly and Assembly UENR0132 Procedure
What code are you troubleshooting? __________
Follow the correct troubleshooting procedure. Reference Table 1 for correct media number to use.
When troubleshooting procedure requests the DEF quality check, DEF injector resistance measurement, or Dosing Accuracy Test, document those results in Tables 2, 3, and 4.Tables
Table 2
DEF Quality Results
Step Instruction Completed (Yes/No) Result Comments Units
1 Follow the Testing and Adjusting procedure for "Diesel Exhaust Fluid Quality - Test"
2 DEF Contamination Test Pass / Fail
3 DEF Concentration Test % at 20° C (68° F)
Illustration 1 g06175415
Table 3
Injector Resistance Measurement
Step Instruction Completed (Yes/No) Result Comments Units
1 Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
2 Disconnect the DEF injectors from the applicable harness.
3 Inspect the connector for damage and debris.
4 Measure the temperature of the injector (aluminum body). C
5 Connect two 398-4987 Probes to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector. Reference Illustration 1 for example.
6 Measure the resistance of the DEF injector. Ohms
Table 4
Dosing Accuracy Test
Step Instruction Completed (Yes/No) Result Comments Units
1 Follow the Testing and Adjusting procedure for "Aftertreatment SCR System Dosing - Test"
2 Remove the injector from the DPF outlet.
3 Take a photograph of the DEF injector mount on the DPF outlet and the tip of the DEF injector.
4 Install the injector on the beaker.
5 Run the DEF System Dosing Accuracy test through Cat® Electronic Technician (ET).
6 Use the beaker to measure the amount of fluid from the dosing test. ml
7 Repeat the test to verify consistency. ml
8 Install the injector back onto the DPF outlet.