101607-1600 ZEXEL 9 400 615 627 BOSCH INJECTION-PUMP ASSEMBLY 9400615627 1016071600 me076772

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 627 9400615627

ZEXEL 101607-1600 1016071600

MITSUBISHI ME076772 me076772

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Buy INJECTION-PUMP ASSEMBLY 101607-1600 zexel genuine, new aftermarket engine parts with delivery

Service parts 101607-1600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9500

3. GOVERNOR 105931-8441

4. SUPPLY PUMP 105210-4641

5. AUTOM. ADVANCE MECHANIS 105643-0750

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105030-4110

14. NOZZLE

15. NOZZLE SET

Include in #1:

101492-0940 as _

101607-1600 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 627 9400615627

ZEXEL 101607-1600 1016071600

MITSUBISHI ME076772 me076772

Zexel num

Bosch num

Firm num

Name

101607-1600

9 400 615 627

ME076772 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 11.2

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 57.7 56 59.4

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. 13.7 11.6 15.8

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 57.7 56.7 58.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 72.6 68.6 76.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 59.7 55.7 63.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+1.25

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 57.1 53.1 61.1

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 130 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

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)RACK LIMIT
----------
T1=F21
----------

Speed control lever angle

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

----------
a=24deg+-5deg b=41deg+-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 = actual (non-injection rack position). (3)Rack position = approximately dd (4)Free (at shipping) (5)Use the hole above R = ee
----------
aa=1550r/min bb=7-0.5mm cc=275r/min dd=15mm ee=40mm
----------
a=36.5deg+-5deg b=(25deg) c=13.5deg+-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=41deg+-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=13deg
----------
a=(0deg)

Information:

ACTION REQUIRED
Replace hoses and clamps with new parts. Refer to the attached Rework Procedure.
OWNER NOTIFICATION
Owners in the following countries will receive the attached Owner Notification:
US
Canada
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 1.5-hour job
Note: 10 Liters of coolant is allowed.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
EXAMPLE COPY OF OWNER NOTIFICATION
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE DEF INJECTOR COOLANT HOSES
MODELS INVOLVED - CERTAIN 313 AND 315 NGH EXCAVATORS
Dear Cat Product Owner:
The existing coolant hoses need to be replaced on the products listed below. The existing hoses can leak water and/or burst. You will not be charged for the service performed.
Contact your local Cat dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
If you are no longer the owner of this product(s), please contact your local Cat dealer so that our records can be updated. Please refer the dealer to their Service Letter dated 01Jul2020 when scheduling this service. Please refer the dealer to their Service Letter dated 12Aug2020 when scheduling this service.
We regret the inconvenience this may cause you, and urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 12Aug2020 Service Letter
Rework Procedure
1. Confirm the machine/engine components/coolant are cooled down for safety.
2. Drain coolant (approximately 10L) to avoid spilling out from hoses during replacement.
3. Removed the strap on hose. Refer to Image1.3.1.
Image1.3.1
4. Loosen the clamps and remove the hoses (both inlet and outlet). Refer to Image1.4.1.
Image1.4.1
5. Install new parts. Refer to Images1.5.1 and 1.5.2.
Image1.5.1
Image1.5.2
6. Fill the coolant and check for leakage from the hoses.