101607-1491 ZEXEL 9 400 610 239 BOSCH INJECTION-PUMP ASSEMBLY 9400610239 1016071491

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 239 9400610239

ZEXEL 101607-1491 1016071491

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Buy INJECTION-PUMP ASSEMBLY 101607-1491 zexel genuine, new aftermarket engine parts with delivery

Service parts 101607-1491 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9540

3. GOVERNOR 105921-5331

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105672-0110

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4901

11. Nozzle and Holder ME086584

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE 105017-0890

15. NOZZLE SET

Include in #1:

101607-1491 as INJECTION-PUMP ASSEMBLY

Include in #2:

104742-1640 as _

Cross reference number

BOSCH 9 400 610 239 9400610239

ZEXEL 101607-1491 1016071491

Zexel num

Bosch num

Firm num

Name

101607-1491
101607-1492

9 400 610 239

INJECTION-PUMP ASSEMBLY
* K 14BE PE6A PE

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 131424-6220

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Drive 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 11.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 56.4 54.8 58

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 12.2 10.9 13.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 56.4 55.4 57.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 64.6 60.6 68.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.6

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 44.4 40.4 48.4

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 73 78

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500+50

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 1 0.5 1.5

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=G09
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(40.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Free (at shipping) (2)Use the hole at R = aa (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd (non-injection rack position). (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1600r/min dd=6.5-0.5mm ee=275r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg

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=10deg
----------
a=(5deg)

Information:

The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
TERMINATION DATE
30Apr2020
PROBLEM
The existing fuel injectors can fail on certain C11 and C13 Industrial Engines. If the existing injectors fail it can create performance issues.
AFFECTED PRODUCT
Model Identification Number
C11 HRA03484-03495
C13 RRA13574, 13576-13578, 13580, 13582-13583, 13585-13588, 13591, 13593-13597, 13599, 13603-13608
PARTS NEEDED
Qty
Part Number Description
6 2490713 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Remove the existing injectors and install new injectors.
C11 - RENR8632, "Electronic Unit Injectors- Remove", "Electronic Unit Injector- Install"
C13 - KENR8165, "Electronic Unit Injector - Remove and Install"
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-12 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.