Information injection-pump assembly
BOSCH
9 400 611 161
9400611161
ZEXEL
101495-3423
1014953423
Rating:
Service parts 101495-3423 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6205-11-3100
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101495-3423
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-7110
as _
Cross reference number
BOSCH
9 400 611 161
9400611161
ZEXEL
101495-3423
1014953423
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
3.2
3.15
3.25
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
10.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
63.5
62.5
64.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.4+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
8
7
9
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)At governor adjustment, set the stop lever at the normal position.
(3)Tolerance for racks not indicated: +-0.05mm.
(4)RACK CAP: R1
(5)Set idle sub-spring
----------
K=12 R1=(17.5)mm
----------
----------
K=12 R1=(17.5)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa. ( At delivery )
(2)Set the pump speed at bb.
(3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=1deg+-5deg b=22deg+-5deg c=6deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=1deg+-5deg b=22deg+-5deg c=6deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, speed = bb (stamp at delivery)
(2)No return spring
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)
----------
aa=1-0.5mm bb=0r/min
----------
a=27.5deg+-5deg b=(55deg)
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)-
(5)-
----------
----------
a=58deg+-3deg b=2deg+-30min
----------
----------
a=58deg+-3deg b=2deg+-30min
Information:
Introduction
Correction to D3G failures of the fuel injection pumpProblem
The D3G has had failures of the fuel injection pump. The failures are seen as low power, running rough, smoking, and hard starting. The failures occur from 8 to 1350 hours. Most failures have been concentrated in the 8 to 400 hour range. There appears to be no environmental aspects or application aspects to the failures at this time. Solution
The rotary fuel pump that is used on the Track-Type Tractors uses diesel fuel for lubrication of the pump. One plunger is used for all 6 injectors. This increases the sensitivity to fuel quality. Customers that are having problems should use 256-4968 Fuel Conditioner . This should help fuel quality by increasing the lubrication. This additive can also be used with low sulfur diesel. Use this fuel conditioner according to directions. For more information, refer to , PELJ0525, "Introducing New Cat Diesel Fuel Conditioner". Low sulfur diesel is already available in many states per the 2007 Highway Diesel Rule. Refer to the following map that shows the areas that produce lower sulfur diesel fuel.
Illustration 1 g01229705
Note: Toyu fuel is not suitable for use in these machines. Toyu fuel does not provide any lubrication for the pump. Using this fuel may cause early failures.
Correction to D3G failures of the fuel injection pumpProblem
The D3G has had failures of the fuel injection pump. The failures are seen as low power, running rough, smoking, and hard starting. The failures occur from 8 to 1350 hours. Most failures have been concentrated in the 8 to 400 hour range. There appears to be no environmental aspects or application aspects to the failures at this time. Solution
The rotary fuel pump that is used on the Track-Type Tractors uses diesel fuel for lubrication of the pump. One plunger is used for all 6 injectors. This increases the sensitivity to fuel quality. Customers that are having problems should use 256-4968 Fuel Conditioner . This should help fuel quality by increasing the lubrication. This additive can also be used with low sulfur diesel. Use this fuel conditioner according to directions. For more information, refer to , PELJ0525, "Introducing New Cat Diesel Fuel Conditioner". Low sulfur diesel is already available in many states per the 2007 Highway Diesel Rule. Refer to the following map that shows the areas that produce lower sulfur diesel fuel.
Illustration 1 g01229705
Note: Toyu fuel is not suitable for use in these machines. Toyu fuel does not provide any lubrication for the pump. Using this fuel may cause early failures.