101608-1380 ZEXEL 9 400 610 752 BOSCH INJECTION-PUMP ASSEMBLY 9400610752 1016081380

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 752 9400610752

ZEXEL 101608-1380 1016081380

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Buy INJECTION-PUMP ASSEMBLY 101608-1380 zexel genuine, new aftermarket engine parts with delivery

Service parts 101608-1380 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8720

3. GOVERNOR 105492-7360

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105643-0990

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4130

11. Nozzle and Holder ME078066

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-3350

14. NOZZLE

105015-8480

15. NOZZLE SET

Include in #1:

101608-1380 as INJECTION-PUMP ASSEMBLY

107692-1480 as _

Cross reference number

BOSCH 9 400 610 752 9400610752

ZEXEL 101608-1380 1016081380

Zexel num

Bosch num

Firm num

Name

101608-1380
101608-1381

9 400 610 752

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 131424-5520

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 4.5 4.45 4.55

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 A

Rack position 10.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 82 81 83

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.6

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 100 96 104

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 11.5 10 13

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 1200--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting (3)Damper spring setting
----------

----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(18deg)+-5deg b=(6deg)+-5deg

0000000901

F:Full load (1)Fix the lever at the full load position
----------

----------
a=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set stopper bolt so that rack position = aa (after adjusting, apply red paint). (2)Drive side
----------
aa=5.9-0.5mm
----------
a=57deg+-5deg b=52deg+7eg-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=12deg
----------
a=(0deg)

Information:

Table 1
Diagnostic Trouble Codes
J1939 Code and Description CDL Code and Description
4334–20
Aftertreatment #1 DEF #1 Pressure (absolute) : Data Drifted High 3090–20
Aftertreatment #1 DEF Pressure Sensor : Data Drifted High
4334-21
Aftertreatment #1 DEF #1 Pressure (absolute) : Data Drifted Low 3090-21
Aftertreatment #1 DEF Pressure Sensor : Data Drifted Low
3361-5
Aftertreatment #1 DEF Dosing Unit : Current Below Normal 3821-5
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator : Current Below Normal
3361-6
Aftertreatment #1 DEF Dosing Unit : Current Above Normal 3821-6
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator : Current Above Normal
3516-12
Aftertreatment #1 DEF Concentration : Failure 3100-12
Aftertreatment #1 DEF Tank Fluid Quality Sensor : Failure
Table 2
Event Codes
J1939 Code and Description CDL Code and Description
5392-31
Aftertreatment Diesel Exhaust Fluid Dosing Unit Loss of Prime E1370 (2)
Aftertreatment #1 DEF Dosing Unit Loss of Prime
4334-18
Aftertreatment #1 DEF #1 Pressure (absolute) : Low - moderate severity (2) E931 (2)
Low Aftertreatment #1 DEF Pressure
4334-16
Aftertreatment #1 DEF #1 Pressure (absolute) : High - moderate severity (2) E930 (2)
High Aftertreatment #1 DEF Pressure
3516-16
Aftertreatment #1 DEF Concentration : High - moderate severity (2) E1365 (2)
High Aftertreatment #1 DEF Concentration
3516-18
Aftertreatment #1 DEF Concentration : Low - moderate severity (2) E1364 (2)
Low Aftertreatment #1 DEF Concentration
5246-15
Aftertreatment SCR Operator Inducement Severity : High - least severe (1) E1389 (1)
Aftertreatment #1 SCR Operator Inducement
5246-16
Aftertreatment SCR Operator Inducement Severity : High - moderate severity (2) E1389 (2)
Aftertreatment #1 SCR Operator Inducement
5246-0
Aftertreatment SCR Operator Inducement Severity : High - most severe (3) E1389 (3)
Aftertreatment #1 SCR Operator Inducement Ensure that DEF fluid conforms to specification ISO 22241 requirements and fluid handling, filling, and storage procedures are strictly followed.All transfer equipment and storage containers should be used exclusively for DEF and should not be reused for other fluids. For example coolants, fuels, oils, and windshield washer fluid.If contamination of the DEF system is suspected, refer to Troubleshooting, DEF Concentration is Incorrect. Ensure that the correct troubleshooting steps are followed. To test for contamination of the DEF tank, refer to Systems Operation Testing and Adjusting, Diesel Exhaust Fluid Quality - Test.If the DEF is contaminated, Caterpillar recommends that the DEF tank is flushed. Refer to Systems Operation Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush for the correct procedure.