Information injection-pump assembly
BOSCH
9 400 619 516
9400619516
ZEXEL
101608-6490
1016086490
Rating:
Service parts 101608-6490 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME441452
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Include in #1:
101608-6490
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-0735
as _
Cross reference number
BOSCH
9 400 619 516
9400619516
ZEXEL
101608-6490
1016086490
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)
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
11.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
126
125
127
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Boost pressure
kPa
52.7
52.7
Boost pressure
mmHg
395
395
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.5+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
16.5
15
18
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
12.3++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
115
115
125
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
9.8
Boost pressure
kPa
9.3
6.6
12
Boost pressure
mmHg
70
50
90
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
11.5
Boost pressure
kPa
39.3
32.6
46
Boost pressure
mmHg
295
245
345
Timer adjustment
Pump speed
r/min
[N1+50]-
-
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
3
2.5
3.5
Load
0/4
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_03
Pump speed
r/min
-
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
N1
Advance angle
deg.
0.5
Load
4/4
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
1.5
1
2
Load
4/4
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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
----------
K=6 BCL=1.7+-0.1mm
----------
----------
K=6 BCL=1.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)When pump speed set at bb
(3)Stopper bolt setting
----------
aa=900r/min bb=755r/min
----------
a=20deg+-5deg b=9deg+-5deg c=6deg+-5deg
----------
aa=900r/min bb=755r/min
----------
a=20deg+-5deg b=9deg+-5deg c=6deg+-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)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=7deg
----------
a=(3deg)
----------
aa=7deg
----------
a=(3deg)
Information:
TERMINATION DATE
30Sep2014
PROBLEM
The existing fuel injectors can experience solenoid valve poppet seizures or poppet binding within injector body due to excessive thermal expansion. If the existing fuel injector fails it can result in complaints of misfire and/or low power.
AFFECTED PRODUCT
Model Identification Number
AD55B JNW00101-00151, 153-155, 157-166, 168-199, 201-244, 246, 248-269, 272-275, 60250
PARTS NEEDED
Qty
Part Number Description
12 8S9191 BOLT
24 3565212 BOLT-12 POINT HD
12 3740751 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% 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
A fuel injector is considered failed if the following troubleshooting Step 1 and Step 2 are completed and the problem is not resolved. Troubleshooting is not cover by this letter.
1. Ensure ECM software is current.
2. Perform the following procedures:
KENR5424 ? Troubleshooting
SENR9937 - Electronic Unit Injector ? Adjust
SENR9937 - Electronic Unit Injector - Test
3. Replace injector(s) as required.
If one or more injectors fail replace all injectors at the time of repair.
Refer to Disassembly and Assembly, RENR9217 for the removal and installation procedure of the unit injector.
8S-9191 Injector Hold Down Bolt must be replaced. Ensure that the proper torque is achieved, 55 +/- 10 Nm (41 +/- 7 lb ft).
356-5212 Rocker Arm Shaft Hold Down Bolts must be replaced. Ensure that proper torque procedure is adhered to.
1. Position rocker arm shaft assembly (4) , valve rocker arms (3) , and electronic unit injector rocker arms (1) as a unit with 124-2946 Lifting Bracket on the cylinder head.
Note: Apply clean engine oil to the underside of the bolt heads prior to installation.
2. Install bolts (2) and tighten to a torque of 55 +/- 5 Nm (41 +/- 4 lb ft). Tighten bolts (2) again to a torque of 55 +/- 5 Nm (41 +/- 4 lb ft). Turn bolts (2) for an additional 60 +/- 5 degrees. Tighten the bolts in the following sequence: 2, 3, 1, 4.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-6000 hrs,
0-18 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 16.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.