Information injection-pump assembly
BOSCH
9 400 610 395
9400610395
ZEXEL
101401-2341
1014012341
Rating:
Service parts 101401-2341 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2161A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 395
9400610395
ZEXEL
101401-2341
1014012341
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
131424-5720
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
4.4
4.35
4.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.5
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
85.5
83.5
87.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
22.7
22.7
Boost pressure
mmHg
170
170
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.8+-0.5
Pump speed
r/min
460
460
460
Average injection quantity
mm3/st.
9
7.5
10.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
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
900
900
900
Rack position
R1-0.6
Boost pressure
kPa
6
6
8
Boost pressure
mmHg
45
45
60
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Rack position
R1(9.5)
Boost pressure
kPa
13.3
10.6
16
Boost pressure
mmHg
100
80
120
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1150
Advance angle
deg.
1.5
1.2
1.8
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
2
2
2
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)Set idle sub-spring
(5)Main spring setting
(6)Boost compensator stroke
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=12deg+-5deg b=25deg+-5deg
----------
----------
a=12deg+-5deg b=25deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)At delivery
(3)Stopper bolt setting
(4)Stopper bolt setting
(5)Use the hole above R = cc
----------
aa=0r/min bb=1-0.5mm cc=25mm
----------
a=13deg+-5deg b=50deg+-5deg
----------
aa=0r/min bb=1-0.5mm cc=25mm
----------
a=13deg+-5deg b=50deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
Caterpillar: Confidential Yellow
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PS0456 - MAILED CFEL
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
E-81 1100, 1290 PS0456 This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0456" as Part Number, "7755" as Group Number, and "96" as Description Code. If this Program is administered on E200B or EL200B Excavators, it is recommended that the June 23, 1990 Service Letter - PS4442 be done at the same time. Termination Date
June 30, 1991
Problem
The fuel injector sleeves in the cylinder head of certain IT14B Integrated Toolcarriers; E110B, E120B, E200B, EL200B, 213B, 214B, 224B, E240B, and EL240B Excavators; 446 Backhoe Loaders; and 3114 and 3116 Industrial and Generator Set Engines are subject to pitting and erosion due to fuel cavitation between the injector and the sleeve. The sleeves may pit or crack through, allowing fuel to contaminate the coolant. Coolant contaminated with fuel may also damage the radiator and coolant hoses.
Affected Product
Model Identification Number IT14B 3NJ1-42 E110B 8MF1-151 E120B 6JF1-212 E200B* 6KF1-439 6KG1-249 EL200B* 7DF1-986 213B 1EJ1-233, 236-245, 247, 248 214B 4CF1-261, 263, 265-275, 278 9MF1-171, 173-182, 185 224B 7WF1-47, 51, 56, 65 E240B 8SF1-36 9PF1-196 EL240B 5WG1-166 6MG1-104 446 6XF1-227 3114 5EF1-675 6AF1-581 1ZG1-432 5JG1-743 3116 2SG1-936 2WG1-859 4PG1-611 1NJ1-999 * The E200B and EL200B Excavators need to be updated to a new injector design released for that machine. The new injectors have a different orifice size to help eliminate black smoke problems reported on some earlier machines. When replacing injectors on E200B and EL200B Excavators, use injector part number 7E8729 if available. Reset the fuel setting and timing if the injectors are available.
PSP FOR REPLACING ERODED CYLINDER HEAD INJECTOR SLEEVES IN CERTAIN IT14B INTEGRATED TOOLCARRIERS; E110B, E120B, E200B, EL2 00B, 213B, 214B, 224B, E240B, EL240B EXCAVATORS; 446 BACKHOE LOADERS; AND 3114 AND 3116 INDUSTRIAL AND GENERATOR SET EN GINES - PS0456 - MAILED CFEL
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
E-81 1100, 1290 PS0456 This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0456" as Part Number, "7755" as Group Number, and "96" as Description Code. If this Program is administered on E200B or EL200B Excavators, it is recommended that the June 23, 1990 Service Letter - PS4442 be done at the same time. Termination Date
June 30, 1991
Problem
The fuel injector sleeves in the cylinder head of certain IT14B Integrated Toolcarriers; E110B, E120B, E200B, EL200B, 213B, 214B, 224B, E240B, and EL240B Excavators; 446 Backhoe Loaders; and 3114 and 3116 Industrial and Generator Set Engines are subject to pitting and erosion due to fuel cavitation between the injector and the sleeve. The sleeves may pit or crack through, allowing fuel to contaminate the coolant. Coolant contaminated with fuel may also damage the radiator and coolant hoses.
Affected Product
Model Identification Number IT14B 3NJ1-42 E110B 8MF1-151 E120B 6JF1-212 E200B* 6KF1-439 6KG1-249 EL200B* 7DF1-986 213B 1EJ1-233, 236-245, 247, 248 214B 4CF1-261, 263, 265-275, 278 9MF1-171, 173-182, 185 224B 7WF1-47, 51, 56, 65 E240B 8SF1-36 9PF1-196 EL240B 5WG1-166 6MG1-104 446 6XF1-227 3114 5EF1-675 6AF1-581 1ZG1-432 5JG1-743 3116 2SG1-936 2WG1-859 4PG1-611 1NJ1-999 * The E200B and EL200B Excavators need to be updated to a new injector design released for that machine. The new injectors have a different orifice size to help eliminate black smoke problems reported on some earlier machines. When replacing injectors on E200B and EL200B Excavators, use injector part number 7E8729 if available. Reset the fuel setting and timing if the injectors are available.