Information injection-pump assembly
BOSCH
9 400 619 505
9400619505
ZEXEL
101608-6371
1016086371
Rating:
Service parts 101608-6371 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME440837
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101608-6371
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-0523
as _
Cross reference number
BOSCH
9 400 619 505
9400619505
ZEXEL
101608-6371
1016086371
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
255
255
Overflow valve opening pressure
kgf/cm2
2.6
2.6
2.6
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.5
3.45
3.55
Beginning of injection position
Drive side NO.1
Drive 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
8.3
Pump speed
r/min
1025
1025
1025
Average injection quantity
mm3/st.
84
83
85
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
8.5
7.2
9.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
8.5++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
65
70
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
R1-0.9
Boost pressure
kPa
30.7
25.4
36
Boost pressure
mmHg
230
190
270
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
R1(8.3)
Boost pressure
kPa
46.7
46.7
46.7
Boost pressure
mmHg
350
350
350
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
3
2.5
3.5
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
750+-25
Advance angle
deg.
0
0
0
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
----------
K=12 BCL=0.9+-0.1mm
----------
----------
K=12 BCL=0.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Base lever only
----------
----------
a=4deg+-5deg b=20deg+-5deg
----------
----------
a=4deg+-5deg b=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Rack position = aa, speed = bb (stamp at delivery)
(3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=25mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=1-0.5mm bb=0r/min cc=25mm
----------
a=21deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=8deg
----------
a=(130deg)
----------
aa=8deg
----------
a=(130deg)
Information:
PARTS NEEDED
Qty
Part Number Description
6 10R7222 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Take the following actions before or after a failure occurs on one or more injectors in any of the machines listed in this service letter.
- If one or more injectors fail it may be necessary to replace up to 6 injectors at the time of repair.
There will be situations when all 6 injectors do not have to be replaced. Refer to next paragraph to determine which injectors should be replaced.
- If an injector repair has previously been performed after approximately 01Oct07 on any of the listed machines, only the injectors that were not replaced at that time should be replaced. This should further be verified by comparing the injector serial numbers in the engine to a range of 3B115776403B to 3B11676551F9. Disregard the first and last two characters in the serial number (in this case "3B" and "3B" in the first serial number and "3B" and "F9" in the second serial number). The reason for verifying the serial number range is due to a batch change of the internal part that is failing. The change was made after serial number 3B11676551F9.
Only injectors falling within the range of 11577640-11676551 should be replaced.
- If the suspect injector can not be identified by using the automatic cylinder cutout test use the two methods below.
- First, run a manual cylinder cutout test at a high engine speed with some load on the engine. When the injector that has failed is cutout, the sound of the engine should be more normal as opposed to the loud knocking heard when the failed injector is active. The second method is to unplug the wiring harness at the valve cover base that sends current to the injector solenoids as well as the harness connection for the injection actuation pressure sensor. By making these disconnections, the fuel injectors will not fire and the HEUI pump will go to maximum actuation pressure. Then remove the valve cover and crank the engine. The injectors that have failed should expel more oil (from the HEUI System) than those that are not failed.
-Refer to RENR9579 for removal/install procedure of the unit injector.
-The serial number of all injectors replaced in a machine covered under this service letter must be documented in the claims story.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-1000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
The serial number of any injector(s) replaced in a machine covered under this service letter must be documented in the claims story. Only injectors with serial numbers between 11577640-11676551 (see action required for explanation on how to decode injector serial number) will be