101608-1203 ZEXEL 9 400 615 785 BOSCH INJECTION-PUMP ASSEMBLY 9400615785 1016081203 me075645

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 785 9400615785

ZEXEL 101608-1203 1016081203

MITSUBISHI ME075645 me075645

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Service parts 101608-1203 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8851

3. GOVERNOR 105932-1452

4. SUPPLY PUMP 105210-6020

5. AUTOM. ADVANCE MECHANIS 105672-5230

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7183

11. Nozzle and Holder ME075761

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

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET

105019-0371

Include in #1:

101608-1203 as INJECTION-PUMP ASSEMBLY

Include in #2:

109341-1032 as _

Cross reference number

BOSCH 9 400 615 785 9400615785

ZEXEL 101608-1203 1016081203

MITSUBISHI ME075645 me075645

Zexel num

Bosch num

Firm num

Name

101608-1203
101608-1910

9 400 615 785

ME075645 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D17-2 K 14BF INJECTION PUMP ASSY PE6AD 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 131424-8420

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 11.9

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 81.5 79.1 83.9

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 600 600 600

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(11.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 81.5 80.5 82.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 88 84 92

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 59.5 55.5 63.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 85 105

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 1100

Advance angle deg. 1 0.5 1.5

Timer adjustment_05

Pump speed r/min 1400

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 (4)Set using the changeover lever.
----------
T1=L13
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=(47.5deg)+-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

0000001201

F:At operation, hold it in the full speed position. I:Idle (1)At rack position aa and pump speed bb, set the stopper bolt. (After setting it, apply red paint.) (2)Actual measurement
----------
aa=9.9+-0.1mm bb=1575r/min
----------
a=15deg+-5deg

0000001501 MICRO SWITCH

Adjust the bolt to obtain the following lever position when the micro-switch is ON. 1. Microswitch adjustment (OPEN type) Confirm with the lever angle at full. (1)Speed N1 (2)Rack position Ra 2. Idle side microswitch adjustment (OPEN type) Confirm with the lever angle at idle. (1)Speed N2 (2)Rack position Rb
----------
N1=1675r/min Ra=9.9+-0.1mm N2=275r/min Rb=9.7+-0.1mm
----------

0000001601 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------

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=(4deg)

Information:

Solution
Caterpillar is aware of this problem and is recommending the following interim corrective action. Please follow the Special Instruction, M0110497, "Removal and Installation Procedure for DEF Heated Lines on Certain Machine Engines" for proper Disassembly and Assembly of the DEF heated lines to avoid failures. If a failure or DEF leak is noted even after following the special instructions, please use Service Magazine, M0103829, "Diesel Exhaust Fluid (DEF) Heated Lines May Be Damage on Certain Cat® Machines" for a temporary line repair. If additional help is needed, please go to the Parts Tech tab and enter a Product Health ticket in PSCRM.The new hose assemblies are listed in Table 1.
Table 1
Item Qty New Part Number Part Name
1 1 457-9011 Return Hose Assembly
2 1 457-9013 Return Hose Assembly
3 1 457-9026 Return Hose Assembly
4 1 457-9027 Return Hose Assembly
5 1 462-4206 Hose As
6 1 462-4210 Hose As
7 1 462-4211 Hose As
8 1 462-4219 Hose As
9 1 462-4220 Hose As
10 1 462-4221 Hose As
11 1 462-4223 Hose As
12 1 462-4224 Hose As
13 1 475-3231 Hose As
14 1 475-3232 Hose As
15 1 475-3233 Hose As
16 1 475-3234 Hose As
17 1 475-9989 Hose As
18 1 478-9071 Hose As
19 1 478-9072 Hose As
20 1 478-9074 Hose As
21 1 478-9075 Hose As
22 1 478-9077 Hose As
23 1 478-9078 Hose As
24 1 478-9079 Hose As
25 1 478-9081 Hose As
26 1 478-9082 Hose As
27 1 478-9083 Hose As
28 1 478-9085 Hose As
29 1 478-9086 Hose As
30 1 497-9305 Hose As
31 1 497-9306 Hose As
32 1 497-9307 Hose As
33 1 497-9308 Hose As
34 1 500-6215 Return Hose Assembly
35 1 500-6216 Return Hose Assembly
36 1 500-6217 Hose As
37 1 500-6218 Hose As
38 1 500-6219 Hose As
39 1 500-6220 Hose As
40 1 500-6221 Hose As
41 1 500-6222 Hose As
42 1 500-6223 Hose As
43 1 500-6224 Hose As
44 1 510-5191 Return Hose Assembly
45 1 510-5192 Hose As
46 1 510-5193 Hose As
47 1 510-5194 Hose As
48 1 552-3292 Hose As
49 1 552-3293 Hose As
50 1 552-3294 Hose As
51 1 552-3295 Hose As
52 1 579-9200 Hose As
53 1 579-9201 Hose As
54 1 579-9202 Hose As
55 1 579-9203 Hose As