Information injection-pump assembly
BOSCH
9 400 619 647
9400619647
ZEXEL
101452-3040
1014523040
Rating:
Service parts 101452-3040 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
118.{120}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 619 647
9400619647
ZEXEL
101452-3040
1014523040
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
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
1-2-4-3
Pre-stroke
mm
1.5
1.45
1.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cyl.1-2 deg. 90 89.5 90.5
Cyl.1-2 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
Cal 1-3 deg. 270 269.5 270.5
Cal 1-3 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
12
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
45.8
44.8
46.8
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.3+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
11
10
12
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK CAP: R1
(3)Rack difference between N = N1 and N = N2
(4)Idle sub spring setting: L1.
----------
K=15 R1=(17.5)mm N1=900r/min N2=500r/min L1=7.3-0.5mm
----------
----------
K=15 R1=(17.5)mm N1=900r/min N2=500r/min L1=7.3-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Set the pump speed at bb.
(3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=2deg+-5deg b=26deg+-5deg c=7deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=2deg+-5deg b=26deg+-5deg c=7deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=47deg+-5deg b=53deg+-5deg
----------
----------
a=47deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
----------
----------
a=46deg18min+-3deg b=13deg42min+-30min
----------
----------
a=46deg18min+-3deg b=13deg42min+-30min
Information:
Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples.A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken.Always use a separate pump for oil sampling and a separate pump for coolant sampling.Failure to do so may cause a false analysis which could lead to customer and dealer concerns.
New Systems, Refilled Systems, and Converted Systems
Perform an S O S coolant analysis (Level 2) at the following maintenance intervals.
Every Year
Initial 500 service hoursPerform this analysis at the interval that occurs first for new systems, for refilled systems, or for converted systems that use Cat coolant products. This 500 hour check will also check for any residual cleaner that may have contaminated the system.Recommended Sampling Interval for S O S Services Coolant Analysis
Table 1
Recommended Interval
Type of Finished Coolant Level 1 Level 2
Cat DEAC
Cat SCA
Conventional Heavy-Duty Coolants Every 250 hours(1)(2) Yearly(1)(2)(3)
Cat ELC
Cat ELI
Commercial EC-1 Coolants Optional(3) Yearly(3)
(1) The recommended sampling interval for all commercial coolants that meet Cat EC-1 (Engine Coolant specification - 1)
(2) The recommended sampling interval for all conventional heavy-duty coolant/antifreeze.
(3) The Level 2 Coolant Analysis should be performed sooner if a problem is suspected or identified.Note: Check the SCA (Supplemental Coolant Additive) of the conventional coolant at every oil change or at every 250 hours. Perform this check at the interval that occurs first.S O S Services Coolant Analysis (Level 1)
A coolant analysis (Level 1) is a test of the properties of the coolant.The following properties of the coolant are tested:
Glycol concentration for freeze protection and boil protection
Ability to protect from erosion and corrosion
pH
Conductivity
Visual analysis
Odor analysisThe results are reported, and appropriate recommendations are made.S O S Services Coolant Analysis (Level 2)
A coolant analysis (Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the cooling system.The S O S coolant analysis (Level 2) has the following features:
Full coolant analysis (Level 1)
Identification of metal corrosion and of contaminants
Identification of buildup of the impurities that cause corrosion
Identification of buildup of the impurities that cause scaling
Determination of the possibility of electrolysis within the cooling system of the engineThe results are reported, and appropriate recommendations are made.For more information on S O S coolant analysis, consult your Cat dealer.