Information injection-pump assembly
ZEXEL
101608-1510
1016081510
Rating:
Cross reference number
ZEXEL
101608-1510
1016081510
Zexel num
Bosch num
Firm num
Name
101608-1510
INJECTION-PUMP ASSEMBLY
14BE PE6A PE
14BE PE6A PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
54.5
52.9
56.1
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
D
Rack position
8.7+-0.5
Pump speed
r/min
500
500
500
Each cylinder's injection qty
mm3/st.
7.6
6.5
8.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
54.5
53.5
55.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
84
80
88
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1(11.4)
Pump speed
r/min
600
600
600
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.
73
63
83
Fixing the lever
*
Rack limit
*
Injection quantity adjustment_07
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
8.7
7.4
10
Fixing the rack
*
Remarks
(check)
(check)
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1200
Advance angle
deg.
2.7
2.2
3.2
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
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=J32
----------
----------
T1=J32
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=18.5deg+-5deg b=41deg+-3deg
----------
aa=29mm
----------
a=18.5deg+-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 = dd (non-injection rack position).
(3)Rack position = approximately ee (speed lever full, speed = ff).
(4)Free (at delivery)
----------
aa=1450r/min bb=4.7-0.5mm cc=275r/min dd=(6.3)mm ee=15mm ff=0r/min
----------
a=38.5deg+-5deg b=(29deg) c=17deg+-5deg
----------
aa=1450r/min bb=4.7-0.5mm cc=275r/min dd=(6.3)mm ee=15mm ff=0r/min
----------
a=38.5deg+-5deg b=(29deg) c=17deg+-5deg
0000001201
I:Idle
F:At operation, hold it in the full speed position.
(1)At rack position aa and pump speed bb, set the stopper bolt. (After setting it, apply red paint.)
----------
aa=7.6+-0.1mm bb=1500r/min
----------
a=15deg+-5deg b=(36deg)+-3deg
----------
aa=7.6+-0.1mm bb=1500r/min
----------
a=15deg+-5deg b=(36deg)+-3deg
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=16deg
----------
a=(1deg)
----------
aa=16deg
----------
a=(1deg)
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
DEF heated lines can get damaged during handling or other failure modes and leak diesel exhaust fluid on Clean Emission Module (CEM) and other components.Solution
Caterpillar is aware of this problem and is recommending the following interim corrective action.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Rework Procedure
Note: This procedure is meant for temporary repair of a DEF line to allow the machine to be safely transported to the repair shop.
Table 1
Required Parts
Part Number Part Name
473-2053 Diesel Exhaust Fluid Lines Gp (5/16th 90 degree adapter)
473-2055 Diesel Exhaust Fluid Lines Gp (5/16th straight adapter)
473-2056 Diesel Exhaust Fluid Lines Gp (3/8th 90 degree adapter)
473-2057 Diesel Exhaust Fluid Lines Gp (38th 90 Straight adapter)
Table 2
Required Tools
Part Number Part Name
1U-7648 Tube Cutter
Illustration 1 g06433660
Cut the connector end on the corrugated section with the cutter.
Illustration 2 g06433665
Cut the two wires with a tie cutter.
Illustration 3 g06433668
Use a knife or sharp blade to cut the outer sheathing off. Ensure not to cut or damage the inner fluid hose.
Illustration 4 g06433669
Install the hose clamp provided first before installing the connector. Use appropriate size (3/8th or 5/16th) and type (90 degree or straight) fitting.
Illustration 5 g06433672
Fasten the clamp until the two jaws are either in contact or about 2 to 3 mm (0.08 to 0.1 inch) apart.
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
DEF heated lines can get damaged during handling or other failure modes and leak diesel exhaust fluid on Clean Emission Module (CEM) and other components.Solution
Caterpillar is aware of this problem and is recommending the following interim corrective action.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Rework Procedure
Note: This procedure is meant for temporary repair of a DEF line to allow the machine to be safely transported to the repair shop.
Table 1
Required Parts
Part Number Part Name
473-2053 Diesel Exhaust Fluid Lines Gp (5/16th 90 degree adapter)
473-2055 Diesel Exhaust Fluid Lines Gp (5/16th straight adapter)
473-2056 Diesel Exhaust Fluid Lines Gp (3/8th 90 degree adapter)
473-2057 Diesel Exhaust Fluid Lines Gp (38th 90 Straight adapter)
Table 2
Required Tools
Part Number Part Name
1U-7648 Tube Cutter
Illustration 1 g06433660
Cut the connector end on the corrugated section with the cutter.
Illustration 2 g06433665
Cut the two wires with a tie cutter.
Illustration 3 g06433668
Use a knife or sharp blade to cut the outer sheathing off. Ensure not to cut or damage the inner fluid hose.
Illustration 4 g06433669
Install the hose clamp provided first before installing the connector. Use appropriate size (3/8th or 5/16th) and type (90 degree or straight) fitting.
Illustration 5 g06433672
Fasten the clamp until the two jaws are either in contact or about 2 to 3 mm (0.08 to 0.1 inch) apart.
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Mitsubishi
101608-1510
INJECTION-PUMP ASSEMBLY