Information injection-pump assembly
BOSCH
9 400 610 430
9400610430
ZEXEL
101401-9671
1014019671
Rating:
Service parts 101401-9671 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-17D02
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 430
9400610430
ZEXEL
101401-9671
1014019671
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
134424-4120
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
3.2
3.15
3.25
Rack position
Point A R=A
Point A R=A
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
-
Rack position
14.6
Pump speed
r/min
1550
1550
1550
Average injection quantity
mm3/st.
108.5
106.9
110.1
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
13
11.2
14.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(14.6)
Pump speed
r/min
1550
1550
1550
Average injection quantity
mm3/st.
108.5
107.5
109.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
70.6
70.6
Boost pressure
mmHg
530
530
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-1.05
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
88
84
92
Fixing the lever
*
Boost pressure
kPa
70.6
70.6
Boost pressure
mmHg
530
530
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-0.95
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
58
54
62
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R2-0.95
Boost pressure
kPa
10.7
9.4
12
Boost pressure
mmHg
80
70
90
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2(R1-1.
35)
Boost pressure
kPa
57.3
57.3
57.3
Boost pressure
mmHg
430
430
430
Timer adjustment
Pump speed
r/min
1000--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
950
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1550
Advance angle
deg.
5.1
4.6
5.6
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
7
6.5
7.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=L33 BCL=0.95+-0.1mm
----------
----------
T1=L33 BCL=0.95+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=71deg+-5deg b=41deg+-3deg
----------
aa=32mm
----------
a=71deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg
0000001501 POTENTIO METER
(A) : Governor plan view
(B): Potentiometer harness terminal
(C): Potentiometer connection diagram
(D) : Output voltage standard value
(S): Voltage
P/M: potentiometer
(v): output voltage (V)
(p): direction of potentiometer rotation
1. Adjustment procedures
(1)Apply DCV1 to potentiometer harness terminal (B) to obtain the specified output voltage.
(2)Fix the speed lever at the full side.
(3)Loosen the bolt (S), and move the potentiometer from left and right.
(4)Adjust so that the output voltage at full is within the standard values.
(5)Fix bolt (S).
(6)Repeatedly move the speed lever from the full side to the idle side.
(7)Check that it is within the standard values at full and idle.
----------
V1=5+-0.02V
----------
V1=5+-0.02V Va=(5)V Vb=4+-0.2V Vc=0.58+-0.3V
----------
V1=5+-0.02V
----------
V1=5+-0.02V Va=(5)V Vb=4+-0.2V Vc=0.58+-0.3V
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole (position of gear's distinguishing mark) at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=5deg
----------
a=(50deg)
----------
aa=5deg
----------
a=(50deg)
Information:
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.
TERMINATION DATE
31Jul2021
PROBLEM
The Diesel Exhaust Fluid (DEF) supply hose insulation for certain R1700 and R2900 Load Haul Dump machines may not have been installed at the factory. If the insulation is missing it needs to be installed. Without the insulation, heat from the exhaust module could cause damage to the hose connector.
AFFECTED PRODUCT
Model Identification Number
R1700K KT400125-00178
R2900 ZLK00125, 127-137
PARTS NEEDED
Qty
Part Number Description
7 2901993 STRAP-CABLE
1 3899442 INSULATION
1 4341304 INSULATION
1 4341305 INSULATION
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 8% 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
Refer to the Service Manual if/as necessary and see Service Magazine M0116960 to install the Diesel Exhaust Fluid (DEF) supply hose insulation.
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,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.