101607-1510 ZEXEL 9 400 615 622 BOSCH INJECTION-PUMP ASSEMBLY 9400615622 1016071510 me076736

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 622 9400615622

ZEXEL 101607-1510 1016071510

MITSUBISHI ME076736 me076736

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Buy INJECTION-PUMP ASSEMBLY 101607-1510 zexel genuine, new aftermarket engine parts with delivery

Service parts 101607-1510 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9080

3. GOVERNOR 105931-8241

4. SUPPLY PUMP 105210-4910

5. AUTOM. ADVANCE MECHANIS 105643-0330

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6030

11. Nozzle and Holder ME035655

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE 105015-5700

15. NOZZLE SET

Include in #1:

101401-7470 as _

101607-1510 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 622 9400615622

ZEXEL 101607-1510 1016071510

MITSUBISHI ME076736 me076736

Zexel num

Bosch num

Firm num

Name

101607-1510

9 400 615 622

ME076736 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D14 * 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 10.8

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 65 63 67

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

Each cylinder's injection qty mm3/st. 10.5 9 12

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 65 64 66

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.8)

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 77.5 75.5 79.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.4

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 59.7 55.7 63.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 14.1+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 70 110

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.8

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2.6 2.1 3.1

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

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=D39
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=24deg+-5deg b=42deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use 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). (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1550r/min bb=7.2-0.5mm cc=275r/min dd=8.2mm ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-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
----------

0000001601 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=42deg+-3deg c=24deg+-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=16deg
----------
a=(1deg)

Information:

AFFECTED PRODUCT
Model Identification Number
C9 LFE00178-00180, 182, 193-194, 196, 2025, 2372-2375, 2585-2588, 2594-2595, 2710, 2714-2716, 2718-2722, 2725-2727, 2729, 2731-2741, 2743-2747, 2765-2784, 2831, 2833-2836, 2838-2839, 2841-2843, 2847-2852, 2855, 2857-2858, 2862, 2879, 2881-2886, 2888, 2890-2892, 2894-2896, 2898-2907, 2909, 2914, 2916-2918, 2920-2921, 2923-2924, 2926, 2928, 2931, 2934, 2937, 2986, 2988-2993, 2995-3043, 3045-3065, 3101-3106, 3110-3111, 3113, 3116, 3118, 3120, 3122, 3125, 3127-3129, 3132-3133, 3138, 3149-3168, 3204-3242, 3250, 3258-3343, 3345-3386, 3582-3584, 3590-3604, 3681-3730, 3732-3735, 3738-3739, 3741-3742, 3744-3749, 3791, 3793-3794, 3812-3831, 3866-3880, 3882-3897, 3899-3919, 3950-4020, 4026-4083, 4085-4118, 4121-4122, 4124-4151, 4153-4240, 4242, 4253-4278, 4281-4316, 4383-4384, 4387-4390, 4392-4395, 4398-4492, 4495-4497
PARTS NEEDED
Qty
Part Number Description
1 5734235 INJECTOR GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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
****Parts Stock ****
Remove all 387-9435 Fuel Injectors from dealer parts stock. Refer to the Parts Disposition.
****Affected Product****
Replace the failed 387-9435 Fuel Injector with a 573-4235 Fuel Injector. Refer to the Disassembly and Assembly, RENR7460, "Unit Injector - Remove", and "Unit Injector - Install", for rework instructions.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all parts removed from dealer parts stock.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-192 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job
PARTS DISPOSITION
****Parts Stock****
Hold all 387-9435 Fuel Injectors for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.