Information injection-pump assembly
BOSCH
9 400 611 944
9400611944
ZEXEL
101608-6220
1016086220
Rating:
Service parts 101608-6220 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME078067
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Include in #1:
101608-6220
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-0627
as _
Cross reference number
BOSCH
9 400 611 944
9400611944
ZEXEL
101608-6220
1016086220
Zexel num
Bosch num
Firm num
Name
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
4.5
4.45
4.55
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
A
Rack position
10.6
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
106
105
107
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
44
44
Boost pressure
mmHg
330
330
Injection quantity adjustment_02
Adjusting point
C
Rack position
8+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.5
9.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
R1-0.9
Boost pressure
kPa
20
17.3
22.7
Boost pressure
mmHg
150
130
170
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R1(10.6)
Boost pressure
kPa
30.7
24
37.4
Boost pressure
mmHg
230
180
280
Timer adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Beginning of advance.
Beginning of advance.
Timer adjustment_02
Pump speed
r/min
450
Advance angle
deg.
2
1.5
2.5
Load
0/4
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
(550)
Advance angle
deg.
0
0
0
Load
0/4
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
0.5
Load
4/4
Timer adjustment_05
Pump speed
r/min
1400
Advance angle
deg.
2.5
2
3
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Main spring setting
(4)Set idle sub-spring
(5)Boost compensator stroke: BCL
----------
K=13 BCL=0.9+-0.1mm
----------
----------
K=13 BCL=0.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(29deg)+-5deg b=(18deg)+-5deg
----------
----------
a=(29deg)+-5deg b=(18deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
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=10deg
----------
a=(1deg)
----------
aa=10deg
----------
a=(1deg)
Information:
REM07-17
Reman
August 2007 APPEARANCE CHANGE TO REMAN ELECTRONIC & HEUI? INJECTORS
Announcement
The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat? Reman Electronic & HEUI? Injectors.
In order to improve the salvage of EUI and HEUI injector components Cat Reman is introducing a new Metal Deposition process around the sealing cone/case on electronic injectors and HEUI injectors for the families mentioned above. Validation Tests confirm change will not alter quality, reliability, fit or performance in any way. Appearance with this new Metal Deposition process before and after use for acceptable cases are as shown below (Reference: EI800 (B) Injector assembly).
Effective July 2007, this appearance change affects part numbers in the following families: EI400, EI800, MI550, EI550 Classic and Bridge, EI500 and EI550 with ACERTTM Technology electronic injectors and HEUI series HI300 CAT, HIA250 and HIA450 Injectors. Refer to the table below for a complete part number listing by family.
Features And Benefits
Cat Remanufactured injectors offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these Remanufactured injectors. Cat Remanufactured injectors provide immediate, off-the-shelf availability at a fraction of the new price.
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. Consult your Core Acceptance Guide for complete details.
Warranty
Please consult the appropriate warranty statement for your area.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail.
For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD0039), go to the Reman Dealer website https://reman.cat.com
If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman
Technical Help Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0797 CATERPILLAR? ?2007 Caterpillar