Information injection-pump assembly
BOSCH
9 400 613 501
9400613501
ZEXEL
101607-1010
1016071010
MITSUBISHI
ME076603
me076603

Rating:
Service parts 101607-1010 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076614
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
15.
NOZZLE SET
Include in #1:
101607-1010
as INJECTION-PUMP ASSEMBLY
Include in #2:
104701-1060
as _
Cross reference number
BOSCH
9 400 613 501
9400613501
ZEXEL
101607-1010
1016071010
MITSUBISHI
ME076603
me076603
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
131424-5520
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Rack position
(11.2)
Vist
V
1.76
1.76
1.76
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
90.6
89.6
91.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Injection quantity adjustment_02
Rack position
(7.4)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
10.5
8.8
12.2
Max. variation between cylinders
%
0
-15
15
Test data Ex:
Governor adjustment

(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C3=(8deg) t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg C2=0.5--deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N2=800r/min C3=(8deg) t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg C2=0.5--deg R01=0/4load R02=4/4load
Speed control lever angle

N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=1mm bb=16mm
----------
a=31deg+-5deg b=29deg+-5deg
----------
aa=1mm bb=16mm
----------
a=31deg+-5deg b=29deg+-5deg
0000000901

(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=11deg
----------
a=(1deg)
----------
aa=11deg
----------
a=(1deg)
Stop lever angle

(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------
----------
----------
----------
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Caterpillar has discovered that when certain products equipped with the Caterpillar Regeneration System (CRS) are left idling for extended periods of time (greater than 1 hr) and ambient temps are lower than −15° C (5° F), certain conditions may be met which will disable the ability to regenerate the DPF. If the regeneration system cannot activate, the DPF will accumulate too much soot and must eventually be replaced.The issues Caterpillar has identified in extreme cold ambient conditions are the coolant temperature may become too cold for the regeneration system to activate. Also, the pressure lines which connect the DPF inlet section to the DPF intake pressure sensor may collect condensation and freeze. This freezing causes an E1154 (2) or 3609-18 Low DPF #1 Intake Pressure event code. The event code will disable the regeneration until the fault condition goes away.If you suspect low coolant temperature may be contributing to an inability to regenerate the DPF, review the product status report. The product status report is used for investigating the following fault code trend. If coolant temp is the only issue, you will likely see a combination of the following fault codes:
E995 (2) High DPF #1 Soot Loading or 3719-16 Particulate Trap #1 Soot Load Percent : High - moderate severity (2)
Indicates DPF soot load percent has reached 100 percent
E995(3) High DPF #1 soot loading or 3719-0 Particulate Trap #1 Soot Load Percent : High - most severe (3)
Indicates DPF soot load percent has reached 116 percent
E992(3) DPF Active Regeneration Inhibited Due to Temporary System Lockout or 3714-31 Particulate Trap Active Regeneration Inhibited Due to Temporary System Lockout
Indicates DPF soot load reached 116 percent and 10 minutes has passed since that point. Ability to perform automatic or manual regenerations is disabled. Caterpillar Electronic Technician (ET) regeneration is only type of regeneration allowed.
E991 (3) DPF Active Regeneration Inhibited Due to Permanent System Lockout or 3715-31 Particulate Trap Active Regeneration Inhibited Due to Permanent System Lockout
Indicates DPF soot load percent has reached 140 percent. All types of regeneration are disabled. DPF must be replaced as the amount of soot load will damage the DPF if ignited by regeneration process.If you suspect the pressure line for the DPF intake pressure has frozen, you will see a combination of fault codes. These codes will consist of the codes listed above with the addition of the following codes: E1154 (2) DPF #1 intake pressure low and 3609-18 DPF #1 Intake Pressure : Low - moderate severity (2).Solution
Caterpillar recommends the following when extended idling is likely to occur and ambient temperatures are less than −15° C (5° F):
Turn off machine before the end of shift. Before shutting down, perform a manual DPF regeneration and reduce soot load to 0 percent. The soot load must be above the 15 percent threshold needed to activate a manual DPF regeneration.If extended idling is
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Caterpillar has discovered that when certain products equipped with the Caterpillar Regeneration System (CRS) are left idling for extended periods of time (greater than 1 hr) and ambient temps are lower than −15° C (5° F), certain conditions may be met which will disable the ability to regenerate the DPF. If the regeneration system cannot activate, the DPF will accumulate too much soot and must eventually be replaced.The issues Caterpillar has identified in extreme cold ambient conditions are the coolant temperature may become too cold for the regeneration system to activate. Also, the pressure lines which connect the DPF inlet section to the DPF intake pressure sensor may collect condensation and freeze. This freezing causes an E1154 (2) or 3609-18 Low DPF #1 Intake Pressure event code. The event code will disable the regeneration until the fault condition goes away.If you suspect low coolant temperature may be contributing to an inability to regenerate the DPF, review the product status report. The product status report is used for investigating the following fault code trend. If coolant temp is the only issue, you will likely see a combination of the following fault codes:
E995 (2) High DPF #1 Soot Loading or 3719-16 Particulate Trap #1 Soot Load Percent : High - moderate severity (2)
Indicates DPF soot load percent has reached 100 percent
E995(3) High DPF #1 soot loading or 3719-0 Particulate Trap #1 Soot Load Percent : High - most severe (3)
Indicates DPF soot load percent has reached 116 percent
E992(3) DPF Active Regeneration Inhibited Due to Temporary System Lockout or 3714-31 Particulate Trap Active Regeneration Inhibited Due to Temporary System Lockout
Indicates DPF soot load reached 116 percent and 10 minutes has passed since that point. Ability to perform automatic or manual regenerations is disabled. Caterpillar Electronic Technician (ET) regeneration is only type of regeneration allowed.
E991 (3) DPF Active Regeneration Inhibited Due to Permanent System Lockout or 3715-31 Particulate Trap Active Regeneration Inhibited Due to Permanent System Lockout
Indicates DPF soot load percent has reached 140 percent. All types of regeneration are disabled. DPF must be replaced as the amount of soot load will damage the DPF if ignited by regeneration process.If you suspect the pressure line for the DPF intake pressure has frozen, you will see a combination of fault codes. These codes will consist of the codes listed above with the addition of the following codes: E1154 (2) DPF #1 intake pressure low and 3609-18 DPF #1 Intake Pressure : Low - moderate severity (2).Solution
Caterpillar recommends the following when extended idling is likely to occur and ambient temperatures are less than −15° C (5° F):
Turn off machine before the end of shift. Before shutting down, perform a manual DPF regeneration and reduce soot load to 0 percent. The soot load must be above the 15 percent threshold needed to activate a manual DPF regeneration.If extended idling is