Information injection-pump assembly
BOSCH
9 400 613 383
9400613383
ZEXEL
101608-6491
1016086491
Rating:
Service parts 101608-6491 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:
101608-6491
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-0743
as _
Cross reference number
BOSCH
9 400 613 383
9400613383
ZEXEL
101608-6491
1016086491
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
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
12.5
Pump speed
r/min
890
890
890
Average injection quantity
mm3/st.
144
143
145
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
52.7
52.7
Boost pressure
mmHg
395
395
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.7+-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
13.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
145
145
155
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
R1-1.7
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
R1(12.5)
Boost pressure
kPa
39.3
32.6
46
Boost pressure
mmHg
295
245
345
Timer adjustment
Pump speed
r/min
830--
Advance angle
deg.
0
0
0
Load
4/4
Remarks
Beginning of advance.
Beginning of advance.
Timer adjustment_02
Pump speed
r/min
400
Advance angle
deg.
3
2.5
3.5
Load
0/4
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
(550)
Advance angle
deg.
0
0
0
Load
0/4
Timer adjustment_04
Pump speed
r/min
780
Advance angle
deg.
0.5
Load
4/4
Timer adjustment_05
Pump speed
r/min
895
Advance angle
deg.
0.75
0.25
1.25
Load
4/4
Timer adjustment_06
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
(5)Set at delivery
(6)Set idle sub-spring
----------
K=6
----------
----------
K=6
----------
Speed control lever angle
F:Full speed
I:Idle
(1)When pump speed set at aa
(2)Set speed at bb (setting at delivery).
(3)Use the hole above R = cc
(4)Stopper bolt setting
----------
aa=750r/min bb=910r/min cc=70mm
----------
a=20deg+-5deg b=5deg+-5deg c=5deg+-5deg
----------
aa=750r/min bb=910r/min cc=70mm
----------
a=20deg+-5deg b=5deg+-5deg c=5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Use the hole at R = aa
(3)Rack position bb, pump speed cc (seal at delivery)
----------
aa=23mm bb=1-0.5mm cc=0r/min
----------
a=35deg+-5deg b=(55deg)
----------
aa=23mm bb=1-0.5mm cc=0r/min
----------
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:
PARTS NEEDED
Qty
Part Number Description
2 1R1808 FILTER-LUBE
12 8S9191 BOLT
4 3460335 CLAMP-BAND
12 3594050 INJECTOR GP-FUEL
1 BULK_OIL DEO-ULS (See Action Required for Refill Qty)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% 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
If excessive fuel dilution of engine oil is found reference the following documents to determine the cause of fuel dilution.
Special Instruction, REHS3007,"Determining the Cause of Fuel Dilution of Engine Oil"
Troubleshooting, KENR9795, "C27 and C32 Engines for Caterpillar Built Machines"
Once an injector(s) has been identified as having a cracked/leaking injector body, replace the failed injector(s). Inspect the remaining good injector serial numbers with Cat ET, (Injector Serial Numbers = Injector trim file name, (ie 6Cxxxxxxxxxx.trm)). If the remaining injector serial numbers fall within the serial number range below, replace at the same time. Refer to Image 1 for the serial number
location on the top of the electronic unit injector.
Injector Serial Numbers
5C0018195245 - 5C0018588683
6C001930907B - 6C002200848C
If an injector failure occurs on either of the rear two cylinders (right and/or left hand bank) the exhaust piping going from the turbo to the CEM will have to be removed. 346-0335 Exhaust Clamp cannot be reused and MUST be replaced with a new clamp. Refer to REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for the proper installation and removal procedure. Refer to Image 2 for clamp location.
The 8S-9191 Injector Hold Down Bolts must be replaced.
Refer to Disassembly and Assembly, RENR9217 for the removal, installation, and tightening procedures.
After the engine is reassembled, change the engine oil and filters.
The refill capacities are per the Operation and Maintenance Manual.
777G 109 Liters
854K 120 Liters
992K 120 Liters
D11T 103 Liters
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3501-6000 hrs,
25-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 10.0-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.