106651-2531 ZEXEL 9 400 616 565 BOSCH INJECTION-PUMP ASSEMBLY 9400616565 1066512531 me151229

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 565 9400616565

ZEXEL 106651-2531 1066512531

MITSUBISHI ME151229 me151229

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Buy INJECTION-PUMP ASSEMBLY 106651-2531 zexel genuine, new aftermarket engine parts with delivery

Service parts 106651-2531 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106065-5330

3. GOVERNOR 105487-6830

4. SUPPLY PUMP 105207-1041

5. AUTOM. ADVANCE MECHANIS 105636-2490

6. COUPLING PLATE 105662-0710

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5721

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105041-4420

14. NOZZLE

105015-5330

15. NOZZLE SET

Include in #1:

106651-2531 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 565 9400616565

ZEXEL 106651-2531 1066512531

MITSUBISHI ME151229 me151229

Zexel num

Bosch num

Firm num

Name

106651-2531

9 400 616 565

ME151229 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22T0 * K

Calibration Data:

Adjustment conditions

Test oil
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 8-3-600

Overflow valve 131424-4420

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 5.1 5.05 5.15

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 137.4 134 140.8

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.3+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 18.6 15.9 21.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 137.4 136.4 138.4

Basic *

Fixing the lever *

Boost pressure kPa 52 52

Boost pressure mmHg 390 390

Injection quantity adjustment_04

Adjusting point B

Rack position R1(12)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 136.6 132.6 140.6

Difference in delivery mm3/st. 8 8 8

Fixing the lever *

Boost pressure kPa 52 52

Boost pressure mmHg 390 390

Injection quantity adjustment_05

Adjusting point D

Rack position 11.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 121 117.4 124.6

Fixing the lever *

Boost pressure kPa 29.3 28 30.6

Boost pressure mmHg 220 210 230

Injection quantity adjustment_06

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 90 130

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R2(R1-2)

Boost pressure kPa 4 4 4

Boost pressure mmHg 30 30 30

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 11.5

Boost pressure kPa 29.3 28 30.6

Boost pressure mmHg 220 210 230

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position R1(12)

Boost pressure kPa 38.7 32 45.4

Boost pressure mmHg 290 240 340

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 3.5 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Boost compensator cancel stroke: BSL (5)Damper spring setting (6)Boost compensator stroke: BCL
----------
RT=1 TH=2.8mm BSL=2mm BCL=2+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=8.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=36deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Rack position = bb, set the stopper bolt. (3)Free (at delivery)
----------
aa=14mm bb=4.9-0.5mm
----------
a=(35.5deg) b=25.5deg+-5deg c=0deg+7deg-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=6+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(6deg)

Information:

PARTS NEEDED
Qty
Part Number Description
2 5P4115 WASHER-HARD
2 6S8620 CLAMP-HOSE
4 8T4121 WASHER-HARD
2 8T4171 BOLT-HEX HEAD
2 8T4195 BOLT-HEX HEAD
1 3550632 CONNECTOR-SPL
1 4609257 INJECTOR AS-DEF
1 4719926 TANK AS-ALUMINUM
1 4719927 PLATE AS
2 4719928 PLATE AS
9 4721116 HOSE-BULK (9cm)
1 5218238 SFWR GP-A1000
1 BULK_COOLANT COOLANT - See Action Required
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
1. Replace the DEF Injector, As per the Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Please ensure that the coolant drained from the system is stored in a suitable storage container and not refilled until the end of the following procedure.
2. Position bracket assembly 471-9927 onto the CEM. Ensure that the bracket is correctly orientated. As per Image 1
3. Position the two 471-9928 plates onto the CEM and install 8T-4195 bolts with the 8T-4121 washers. As per Image 2
4. Position coolant tank 471-9926 onto bracket. Install bolts 8T-4171 with 5P-4115 washer. Tighten to 9 Nm. As per Image 1
5. Remove coolant supply hose 349-6234 from DEF injector and connect to tank 471-9926 inlet using existing clamp. As per Image 1
6. Connect hose assembly 472-1116 (9cm) to tank 471-9926 and the DEF injector. Secure with 2 off 6S?8620 clamps, As per Image 1
7. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, ?Cooling System Coolant - Change? for the correct procedure. If required, top up the coolant system.
8. Flash the engine ECM with the software or latest available in SIS Web.
For flash programming the engine ECM, refer to Troubleshooting, "Flash Programming".
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%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.