101607-1440 ZEXEL 9 400 615 618 BOSCH INJECTION-PUMP ASSEMBLY 9400615618 1016071440 me076701

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 618 9400615618

ZEXEL 101607-1440 1016071440

MITSUBISHI ME076701 me076701

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101401-7580 as _

Cross reference number

BOSCH 9 400 615 618 9400615618

ZEXEL 101607-1440 1016071440

MITSUBISHI ME076701 me076701

Zexel num

Bosch num

Firm num

Name

101607-1440

9 400 615 618

ME076701 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16 * K

Calibration Data:

Adjustment conditions

Test oil
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

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

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.1

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 63.7 61.8 65.6

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point D

Rack position 8.7+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 10.2 8.7 11.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 63.7 62.7 64.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point C

Rack position R1+0.2

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 41.7 37.7 45.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 63 83

Fixing the lever *

Rack limit *

Injection quantity adjustment_06

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 10 8.5 11.5

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2.7 2.2 3.2

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=F35
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=10deg+-5deg b=(46deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1480r/min bb=6.7-0.5mm cc=275r/min dd=(8.3)-0.5mm
----------
a=11.5deg+-5deg b=(27deg)+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

(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=14deg
----------
a=(0deg)

Information:

Reasonable travel time and mileage will be allowed.
Up to $350 will be allowed for man lift rental to access the injector group.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-500 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
For Group 1 Only:
Step 1: Ensure CEM has cooled prior to beginning work. Use a temp gun to ensure that the temperature of the injector is at a safe to handle temperature.
Image1.1.1
Step 2: Once the CEM is at a safe temperature to begin work, remove air and DEF line connections at the injector. Ensure all permits and appropriate scaffolding or man-lift type equipment with sufficient personnel are on site or available if needed. This procedure may require two individuals with all the required PPE to handle the weight and distance to reach for work to be performed.
Image1.2.1
Step 3: Remove eight bolts and remove injector assembly from the CEM. This step may require two individuals due to the weight of the injector.
Step 4: Remove the nozzle group from the injector.
Image1.4.1
Step 5: Apply Loctite (nickel free) dry film anti-seize on the threads of the 352-0865 nozzle group. Ensure that only the threads receive anti-seize as the nozzle could suffer plugging if anti-seize contaminates the tip. Install the nozzle group with a new gasket onto the injector group and tighten to 9 +/- 2 Nm.
Image1.5.1
Step 6: Reinstall the injector with new nozzle and new gasket into the CEM matching alignment notches and tighten the eight (8) mounting bolts to standard torque. This step may require two individuals due to the weight of the injector.
Image1.6.1
Step 7: Using a stamping die set, the old injector part number must be removed. This can be accomplished using the X stamp and stamping out all of the part numbers (XXXXXXXX) or a grinder can be used to permanently remove the part number.
Step 8: Using the stamping die set, stamp part number 549-2925 on the flange of the injector as shown in image 1.6.1.
Step 9: Install software part number 549-6259 into the dosing cabinet ECM.
Please note that re-commissioning of the SCR system is not required after the software update if the system has already been commissioned.