Information injection-pump assembly
ZEXEL
101609-3410
1016093410
Rating:
Cross reference number
ZEXEL
101609-3410
1016093410
Zexel num
Bosch num
Firm num
Name
101609-3410
INJECTION-PUMP ASSEMBLY
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
131424-3420
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
1-5-3-6-
2-4
Pre-stroke
mm
2.5
2.45
2.55
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.3
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
109
108
110
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
37.3
37.3
Boost pressure
mmHg
280
280
Hydraulic cylinder ON
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.9+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder ON
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80
80
90
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Hydraulic cylinder OFF
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R1-0.95
Boost pressure
kPa
10.7
9.4
12
Boost pressure
mmHg
80
70
90
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
R1(10.3)
Boost pressure
kPa
24
24
24
Boost pressure
mmHg
180
180
180
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)Adjust the secondary timing before adjusting the governor.
(4)RACK LIMIT (When hydraulic cylinder is OFF)
(5)Boost compensator stroke: BCL
(6)When hydraulic cylinder ON: P1
----------
K=11 BCL=0.95+-0.1mm P1=((392)kpa,(4)kgf/cm2)
----------
----------
K=11 BCL=0.95+-0.1mm P1=((392)kpa,(4)kgf/cm2)
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the center hole at R = aa
----------
aa=77mm
----------
a=10deg+-5deg b=31deg+-5deg
----------
aa=77mm
----------
a=10deg+-5deg b=31deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=0deg+-5deg b=53deg+-5deg
----------
----------
a=0deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa).
(3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery).
(4)B.T.D.C.: aa
(5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut.
(6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft.
(7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=20deg bb=0deg
----------
a=54deg54min+-3deg b=10deg+-30min
----------
aa=20deg bb=0deg
----------
a=54deg54min+-3deg b=10deg+-30min
Information:
Caterpillar: Confidential Yellow
PSP FOR THE USE OF TWO CLAMPS TO HOLD THE BODY AND FUEL NOZZLE IN POSITION ON 3406, 3408 AND 3412 ENGINES - MAILED WORLDWIDE EXC EPT CANADA, BRAZIL & CACO
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.
PRODUCT SUPPORT PROGRAM FOR THE USE OF TWO CLAMPS TO HOLD THE BODY AND FUEL NOZZLE IN POSITION ON 3406, 3408 AND 3412 ENGINES, 1252, PS4019 U-74 AU-59 E-47 O-45 TT-12 TA-6 TM-6 This Program can be administered either before or after a failure. In either case the warranty allowances will be the same and contingent damage will not be allowed. The decision whether to apply the Program is made by the dealer. When reporting the repair use "PS4019" as Part Number and "7755" as Group Number. Although products in the field are to be administered as described above, dealers should rework parts stock immediately. Termination Date
September 30, 1986.
Problem
Engines equipped with 4W5719 (3406) or 4W5733 (3408, 3412) Adapter Assemblies use one 4W5717 Clamp to hold the body and fuel nozzle in position. See the Illustration. These adapter assemblies are also used in 0R0977 (3406) 0R0980 (3408) and 0R2659 (3412) Remanufactured Head Assemblies. One clamp does not provide enough force to hold the body and fuel nozzle tight. This permits fuel to leak past the internal parts of the nozzle and cause the nozzle case to bulge or split. This program provides for an additional clamp and bolts to be used with these adapter assemblies. (SEE ILLUSTRATION)
Affected Product
1/850907/01/002
Parts Needed
1-4W5717 Clamp and 2-5P6900 Bolts for each adapter assembly.
Action Required
The new parts should be installed on cylinder heads in parts stock immediately. Only cylinder heads received before this Service Letter need to be checked. The new parts should be installed on products in the field only when the valve cover has been removed for some other repair or inspection. Install the new clamp and bolts 180 deg. from the existing clamp and bolts. Tighten the bolts for the new clamp to 31 +/- 7 N X m (23 +/- 5 lb ft). Check to make sure the bolts for the existing clamp are tightened to the same torque. Then check the torque on the bolts for the new clamp. (SEE ILLUSTRATION)
Parts Disposition
Not applicable.
PSP FOR THE USE OF TWO CLAMPS TO HOLD THE BODY AND FUEL NOZZLE IN POSITION ON 3406, 3408 AND 3412 ENGINES - MAILED WORLDWIDE EXC EPT CANADA, BRAZIL & CACO
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.
PRODUCT SUPPORT PROGRAM FOR THE USE OF TWO CLAMPS TO HOLD THE BODY AND FUEL NOZZLE IN POSITION ON 3406, 3408 AND 3412 ENGINES, 1252, PS4019 U-74 AU-59 E-47 O-45 TT-12 TA-6 TM-6 This Program can be administered either before or after a failure. In either case the warranty allowances will be the same and contingent damage will not be allowed. The decision whether to apply the Program is made by the dealer. When reporting the repair use "PS4019" as Part Number and "7755" as Group Number. Although products in the field are to be administered as described above, dealers should rework parts stock immediately. Termination Date
September 30, 1986.
Problem
Engines equipped with 4W5719 (3406) or 4W5733 (3408, 3412) Adapter Assemblies use one 4W5717 Clamp to hold the body and fuel nozzle in position. See the Illustration. These adapter assemblies are also used in 0R0977 (3406) 0R0980 (3408) and 0R2659 (3412) Remanufactured Head Assemblies. One clamp does not provide enough force to hold the body and fuel nozzle tight. This permits fuel to leak past the internal parts of the nozzle and cause the nozzle case to bulge or split. This program provides for an additional clamp and bolts to be used with these adapter assemblies. (SEE ILLUSTRATION)
Affected Product
1/850907/01/002
Parts Needed
1-4W5717 Clamp and 2-5P6900 Bolts for each adapter assembly.
Action Required
The new parts should be installed on cylinder heads in parts stock immediately. Only cylinder heads received before this Service Letter need to be checked. The new parts should be installed on products in the field only when the valve cover has been removed for some other repair or inspection. Install the new clamp and bolts 180 deg. from the existing clamp and bolts. Tighten the bolts for the new clamp to 31 +/- 7 N X m (23 +/- 5 lb ft). Check to make sure the bolts for the existing clamp are tightened to the same torque. Then check the torque on the bolts for the new clamp. (SEE ILLUSTRATION)
Parts Disposition
Not applicable.
Have questions with 101609-3410?
Group cross 101609-3410 ZEXEL
Komatsu
101609-3410
INJECTION-PUMP ASSEMBLY