101607-6625 ZEXEL 9 400 613 504 BOSCH INJECTION-PUMP ASSEMBLY 9400613504 1016076625

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 504 9400613504

ZEXEL 101607-6625 1016076625

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Service parts 101607-6625 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105932-0003

4. SUPPLY PUMP 105210-6020

5. AUTOM. ADVANCE MECHANIS 105672-5220

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7461

11. Nozzle and Holder ME075405

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

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE 105015-9650

15. NOZZLE SET

Include in #1:

101402-7902 as _

101607-6625 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 504 9400613504

ZEXEL 101607-6625 1016076625

Zexel num

Bosch num

Firm num

Name

101607-6625
101607-6626

9 400 613 504

INJECTION-PUMP ASSEMBLY
* 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 131424-8420

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 3.2 3.15 3.25

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 11.6

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 75.5 73.2 77.8

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 75.5 74.5 76.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.25

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 82.5 78.5 86.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.45

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 48.5 44.5 52.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 115 135

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 1 0.5 1.5

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

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=J96
----------

Speed control lever angle

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

----------
a=18.5deg+-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 (speed lever full, speed = ff). (4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 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=18.5deg+-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=7deg
----------
a=(3deg)

Information:

Illustration 17 g03389921
Illustration 18 g03389931
Read the warning and select "Accept" to continue.
Illustration 19 g03389947
Once the reset is completed, a log of the reset is captured and visible as a new row of information in the Diesel Oxidation Catalyst Replacement screen. Selective Catalytic Reduction (SCR) Maintenance on Tier 4 Final Products
Note: Refer to Table 5 for the existing SCR catalyst part number being serviced along with the corresponding new service kit, and the clamp part number required for reassembly.
Table 5
SCR Part Number Service Kit Part Number Required Clamp Part Number
447-8145 N/A 346-0335
447-8143 N/A 346-0335
447-8141 N/A 346-0335
447-8149 N/A 346-0335
447-8147 N/A 346-0335
447-8163 N/A 346-0335
447-8151 N/A 346-0335
375-0989 N/A 346-0335
447-8165 N/A 346-0335
447-8153 N/A 346-0335
447-8161 N/A 346-0335
447-8159 N/A 346-0335
447-8157 N/A 346-0335
447-8169 N/A 346-0335
447-8173 N/A 346-0335
447-8171 N/A 346-0335
447-8167 N/A 346-0335
447-8175 N/A 346-0335 The Aftertreatment SCR Catalyst Replacement procedure must be performed when the SCR Catalyst has been replaced. This is necessary to ensure that the engine meets emissions requirements. Follow the procedure below to reset the SCR Catalyst model in the aftertreatment software.
Connect to Cat® ET.
Illustration 20 g03390636
Connect to "Engine #1 Aftertreatment Controller".
Illustration 21 g03740190
Select "Service" from the top menu and select "Service Procedures".
Illustration 22 g03740205
Select "Aftertreatment #1 SCR Catalyst Replacement" and select "Start".
Illustration 23 g03740210
Select "Reset".
Illustration 24 g03740216
You must read the warning and select "Accept" to continue.
Enter the factory passwords to continue.
Illustration 25 g03740230
Once the reset is completed, a log of the reset is captured and visible as a new row of information in the "Aftertreatment #1 SCR Catalyst Replacement" screen.