Information injection-pump assembly
BOSCH
9 400 610 702
9400610702
ZEXEL
101605-9452
1016059452
Rating:
Service parts 101605-9452 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5607
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 702
9400610702
ZEXEL
101605-9452
1016059452
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
Overflow valve
131424-1520
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
1-4-2-6-
3-5
Pre-stroke
mm
3.3
3.25
3.35
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
91.5
89.5
93.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_02
Adjusting point
B
Rack position
R1(9.9)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
72
71
73
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
C
Rack position
6.9+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
9
7.2
10.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
R1(9.9)
Boost pressure
kPa
4
4
8
Boost pressure
mmHg
30
30
60
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
(10)
Boost pressure
kPa
12.7
12.7
12.7
Boost pressure
mmHg
95
95
95
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)Boost compensator excessive fuel lever at operation (at 0 boost pressure): L1
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
(7)Rack difference between N = N1 and N = N2
----------
K=10 L1=11.9+-0.1mm BCL=(0.1)mm N1=1100r/min N2=800r/min
----------
----------
K=10 L1=11.9+-0.1mm BCL=(0.1)mm N1=1100r/min N2=800r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(15deg)+-5deg b=(23deg)+-5deg
----------
----------
a=(15deg)+-5deg b=(23deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
0000001101
N:Normal
B:When boosted
(1)Rack position = aa (at 0 boost)
----------
aa=11.9+-0.1mm
----------
a=(15deg) b=(25deg)
----------
aa=11.9+-0.1mm
----------
a=(15deg) b=(25deg)
Timing setting
(1)Pump vertical direction
(2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Diagnostic Lamp
A DIAGNOSTIC lamp may be included with your engine package. The DIAGNOSTIC lamp indicates an engine diagnostic condition or an electronic governing/control system fault. In most cases a diagnostic code will be stored in permanent memory within the ECM. The diagnostic code can be retrieved by either of two methods; 1) electronic service tool or 2) use the DIAGNOSTIC lamp.The engine may be equipped with a DIAGNOSTIC lamp that automatically flashes an active fault code when there is power to the ECM. ACTIVE Codes - represent problem(s) that currently exist and should be investigated first. If a code is active, the Diagnostic lamp will illuminate and blink every five seconds. LOGGED Codes - represent intermittent problem(s) which may have been temporary or repaired since the time code was logged. These codes do not indicate a repair is needed, but instead are guides or signals when an intermittent situation exists, which could be used to troubleshoot and analyze potential problems. In addition, some LOGGED Codes record events and performance history, rather than problems and/or failures.Diagnostic Flash Code Retrieval
If the DIAGNOSTIC lamp is ON during engine operation, the system has detected a system fault. Use the DIAGNOSTIC lamp or electronic service tool to identify the diagnostic code.The DIAGNOSTIC lamp will illuminate (ON) and blink every five seconds whenever a diagnostic fault is detected by the ECM. The lamp should also illuminate (ON) whenever the START switch is turned ON, but the engine is not running. This condition will test whether the lamp is operating correctly. The DIAGNOSTIC lamp will illuminate for five seconds and turn OFF for an intermittent fault (stays ON ONLY if there is an Active Diagnostic Code).If the DIAGNOSTIC lamp comes ON and stays ON after initial start-up, the ECM has detected a system fault. Use the lamp or the ECAP service tool to determine the diagnostic code.The DIAGNOSTIC lamp can be used to communicate the specific diagnostic fault. With the switch depressed, the DIAGNOSTIC lamp will begin to flash. The sequence of flashes represents the system diagnostic message. Count the first sequence of flashes to determine the first digit of the diagnostic code. After a two second pause, the second sequence of flashes will identify the second digit of the diagnostic code. Any additional diagnostic codes will follow (after a pause) and will be displayed in the same manner.Refer to the Electronic Troubleshooting Manual for troubleshooting ELECTRONIC SYSTEM problems, or for further information or assistance, contact your Caterpillar dealer. Permanent Fault Logging
The system provides Permanent Fault Logging. When the ECM generates a diagnostic code, it will log the code in permanent memory. The logged codes can then be retrieved using an electronic service tool.Intermittent Fault
If the diagnostic lamp comes ON during engine operation, and then goes out, an intermittent fault may be occurring. The electronic control engine system is equipped with permanent fault logging. It will automatically log (or remember) most intermittent faults to help a service technician diagnose an engine problem.If there are no
A DIAGNOSTIC lamp may be included with your engine package. The DIAGNOSTIC lamp indicates an engine diagnostic condition or an electronic governing/control system fault. In most cases a diagnostic code will be stored in permanent memory within the ECM. The diagnostic code can be retrieved by either of two methods; 1) electronic service tool or 2) use the DIAGNOSTIC lamp.The engine may be equipped with a DIAGNOSTIC lamp that automatically flashes an active fault code when there is power to the ECM. ACTIVE Codes - represent problem(s) that currently exist and should be investigated first. If a code is active, the Diagnostic lamp will illuminate and blink every five seconds. LOGGED Codes - represent intermittent problem(s) which may have been temporary or repaired since the time code was logged. These codes do not indicate a repair is needed, but instead are guides or signals when an intermittent situation exists, which could be used to troubleshoot and analyze potential problems. In addition, some LOGGED Codes record events and performance history, rather than problems and/or failures.Diagnostic Flash Code Retrieval
If the DIAGNOSTIC lamp is ON during engine operation, the system has detected a system fault. Use the DIAGNOSTIC lamp or electronic service tool to identify the diagnostic code.The DIAGNOSTIC lamp will illuminate (ON) and blink every five seconds whenever a diagnostic fault is detected by the ECM. The lamp should also illuminate (ON) whenever the START switch is turned ON, but the engine is not running. This condition will test whether the lamp is operating correctly. The DIAGNOSTIC lamp will illuminate for five seconds and turn OFF for an intermittent fault (stays ON ONLY if there is an Active Diagnostic Code).If the DIAGNOSTIC lamp comes ON and stays ON after initial start-up, the ECM has detected a system fault. Use the lamp or the ECAP service tool to determine the diagnostic code.The DIAGNOSTIC lamp can be used to communicate the specific diagnostic fault. With the switch depressed, the DIAGNOSTIC lamp will begin to flash. The sequence of flashes represents the system diagnostic message. Count the first sequence of flashes to determine the first digit of the diagnostic code. After a two second pause, the second sequence of flashes will identify the second digit of the diagnostic code. Any additional diagnostic codes will follow (after a pause) and will be displayed in the same manner.Refer to the Electronic Troubleshooting Manual for troubleshooting ELECTRONIC SYSTEM problems, or for further information or assistance, contact your Caterpillar dealer. Permanent Fault Logging
The system provides Permanent Fault Logging. When the ECM generates a diagnostic code, it will log the code in permanent memory. The logged codes can then be retrieved using an electronic service tool.Intermittent Fault
If the diagnostic lamp comes ON during engine operation, and then goes out, an intermittent fault may be occurring. The electronic control engine system is equipped with permanent fault logging. It will automatically log (or remember) most intermittent faults to help a service technician diagnose an engine problem.If there are no