101607-9791 ZEXEL 9 400 615 762 BOSCH INJECTION-PUMP ASSEMBLY 9400615762 1016079791 16714z6016

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 762 9400615762

ZEXEL 101607-9791 1016079791

NISSAN-DIESEL 16714Z6016 16714z6016

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104746-5380 as _

Cross reference number

BOSCH 9 400 615 762 9400615762

ZEXEL 101607-9791 1016079791

NISSAN-DIESEL 16714Z6016 16714z6016

Zexel num

Bosch num

Firm num

Name

101607-9791

9 400 615 762

16714Z6016 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
MD92 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8921

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

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

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

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

Injection quantity adjustment

Adjusting point -

Rack position 11.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 95 93.4 96.6

Max. variation between cylinders % 0 -3.5 3.5

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 280 280 280

Average injection quantity mm3/st. 12 11 13

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(11.8)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 95 94 96

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 100.5 96.5 104.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 125 135

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 970--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 920

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min (1000)

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1160

Advance angle deg. 1.5 1 2

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=L85
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=39mm
----------
a=6.5deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=42mm
----------
a=5deg+-5deg b=40deg+-5deg

0000001501 LEVER

(a) Speed lever (B) Accelerator lever (C) Accelerator lever stopper bolt 1. Accelerator lever setting method With the speed lever in the idling position, back off the accelerator lever stopper bolt L1 from where it contacts point a.
----------
r1=39mm r2=38mm L1=1+0.5mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(75deg)

Information:

Introduction
The EPA has mandated that a DEF quality sensor must be installed on all engines built in 2017 or after. This new DEF quality sensor is integrated into the DEF header inside the DEF tank. The new style DEF header utilizes CAN C communication, so the wiring to the DEF header has been slightly modified on product going forward. However, the DCU remains compatible to both setups with the latest 507-7605 Engine Software. As part of the DEF quality sensor implementation, a new configuration parameter setting is used on the engine ECM in Cat® Electronic Technician (ET) to identify whether a DEF quality sensor is "installed" or "not installed". Below are some different fault codes for incompatible hardware and configuration setting as well as different service scenarios that may be encountered with this change and how to resolve any issues in these particular service scenarios. In addition to this Special Instruction, there is a video detailing these changes posted on Cat Channel 1.Channel1 Video
Note: A CWS login is required to access Caterpillar Channel1. Scan the QR code below with a QR enabled device or copy the link that follows.
Illustration 1 g06462430Reference: For more information, refer to "Diesel Exhaust Fluid Quality Sensor" on Caterpillar Channel1.https://channel1.mediaspace.kaltura.com/media/0_qyokrphe
Fault Codes When Parts/Settings Are Not Compatible
DEF quality header not installed but configuration set to installed.
Table 1
J1939 Code and Description CDL Code and Description
1235-9
J1939 Network #3 : Abnormal Update Rate 5856-9
J1939 Network #3 : Abnormal Update Rate DEF quality header installed but configuration set to not installed.
Table 2
J1939 Code and Description CDL Code and Description
1761-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Voltage Above Normal 3130-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Level Sensor : Voltage Above Normal
3031-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature : Voltage Above Normal 3134-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Temperature Sensor : Voltage Above Normal DEF Quality Sensor Service Scenarios
Listed below are the different examples of when the DEF Quality Sensor and associated components are needed.Replacement Industrial Engine (Built in 2016 or Before)
If these engines are replaced with an engine built in 2017 or after, the following updates will be required:
Updating to a DEF Quality Sensor by installing a new DEF Header
Wiring Harness
DCU Software
Change configuration status to "Installed" in Cat ETReplacement Machine Engine (Built in 2016 or Before)
If this engine is replaced with an engine built in 2016 or a previous Engine Arrangement Complete (EAC) engine, no other changes are needed.Confirm that the "DEF Quality Sensor" configuration is set to "Not Installed" in Cat ET.Replacement Machine Engine (Built in 2016 or Before)
If the engine is replaced with the latest EAC the following updates will be required:
Update to a DEF Quality Sensor by installing a new DEF header
Wiring harness
DCU Software
Change configuration status to "Installed" in Cat ETReplacement Engine (Built in 2017 or After)
Replace the engine with the latest EAC.Installing the DEF Quality Sensor on Engines Built in 2016 or Before
If installing the DEF Quality Sensor on engine built in 2016 or before, the following must be updated as well:
DCU software update
PETU