Information injection-pump assembly
BOSCH
9 400 615 905
9400615905
ZEXEL
101609-3450
1016093450
KOMATSU
3863817
3863817
Rating:
Service parts 101609-3450 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
101609-3450
as INJECTION-PUMP ASSEMBLY
Include in #2:
104265-3021
as _
Cross reference number
BOSCH
9 400 615 905
9400615905
ZEXEL
101609-3450
1016093450
KOMATSU
3863817
3863817
Zexel num
Bosch num
Firm num
Name
101609-3450
9 400 615 905
3863817 KOMATSU
INJECTION-PUMP ASSEMBLY
S6D102E K
S6D102E K
101609-3450
9 400 615 905
6735711410 KOMATSU
INJECTION-PUMP ASSEMBLY
S6D102E K
S6D102E K
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
9.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
92
91
93
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
49.3
49.3
Boost pressure
mmHg
370
370
Hydraulic cylinder ON
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
13
12
14
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.
70
70
80
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
500
500
500
Rack position
R1-0.6
Boost pressure
kPa
22.7
20
25.4
Boost pressure
mmHg
170
150
190
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(10.1)
Boost pressure
kPa
36
36
36
Boost pressure
mmHg
270
270
270
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
(7)Rack difference between N = N1 and N = N2
----------
K=16 BCL=0.6+-0.1mm P1=((392)kPa,(4)kgf/cm2) N1=1000r/min N2=675r/min
----------
----------
K=16 BCL=0.6+-0.1mm P1=((392)kPa,(4)kgf/cm2) N1=1000r/min N2=675r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=15deg+-5deg b=26deg+-5deg
----------
----------
a=15deg+-5deg b=26deg+-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=17deg bb=0deg
----------
a=54deg54min+-3deg b=8deg30min+-30min
----------
aa=17deg bb=0deg
----------
a=54deg54min+-3deg b=8deg30min+-30min
Information:
Caterpillar: Confidential Yellow
PSP FOR INSTALLING NEW FUEL INJECTION LINE BRACKETS AND CLAMPS ON CERTAIN D8L TRACTORS, D9N TRACTORS, 589 PIPELAYERS, 631E SCR APERS, 637E SCRAPERS, 657E SCRAPERS, 768C TRACTORS, 769C TRUCKS, 834B TRACTORS, AND 988B LOADERS - PS4428 - MAILED US AND CA NADA, CACO, COFA, BRAZIL, CFEL, COSA
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.
U-63 A-35 AU-38 B-13 E-39 O-54 1252 PS4428 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4428" as Part Number, "7755" as Group Number, and "96" as Description Code. Termination Date
March 31, 1991
Problem
The fuel lines on certain D8L Tractors, D9N Tractors, 589 Pipelayers, 631E Scrapers, 637E Scrapers, 657E Scrapers, 768C Tractors, 769C Trucks, 834B Tractors, and 988B Loaders may fail. New brackets and clamps can be installed to increase the service life of the fuel injection lines.
Affected Product
Model Identification Number D8L 7YB962 7JC778 D9N 1JD1288, 1295, 1296, 1298-1356, 1358, 1361-2039, 2045, 2048, 2049, 2052 589 31Z423-452 631E 1AB965-1198, 1209 637E 1FB361-416, 418, 422 1JB612-724 657E
PSP FOR INSTALLING NEW FUEL INJECTION LINE BRACKETS AND CLAMPS ON CERTAIN D8L TRACTORS, D9N TRACTORS, 589 PIPELAYERS, 631E SCR APERS, 637E SCRAPERS, 657E SCRAPERS, 768C TRACTORS, 769C TRUCKS, 834B TRACTORS, AND 988B LOADERS - PS4428 - MAILED US AND CA NADA, CACO, COFA, BRAZIL, CFEL, COSA
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.
U-63 A-35 AU-38 B-13 E-39 O-54 1252 PS4428 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4428" as Part Number, "7755" as Group Number, and "96" as Description Code. Termination Date
March 31, 1991
Problem
The fuel lines on certain D8L Tractors, D9N Tractors, 589 Pipelayers, 631E Scrapers, 637E Scrapers, 657E Scrapers, 768C Tractors, 769C Trucks, 834B Tractors, and 988B Loaders may fail. New brackets and clamps can be installed to increase the service life of the fuel injection lines.
Affected Product
Model Identification Number D8L 7YB962 7JC778 D9N 1JD1288, 1295, 1296, 1298-1356, 1358, 1361-2039, 2045, 2048, 2049, 2052 589 31Z423-452 631E 1AB965-1198, 1209 637E 1FB361-416, 418, 422 1JB612-724 657E
Have questions with 101609-3450?
Group cross 101609-3450 ZEXEL
Komatsu
Komatsu
101609-3450
9 400 615 905
3863817
INJECTION-PUMP ASSEMBLY
S6D102E
S6D102E
101609-3450
9 400 615 905
6735711410
INJECTION-PUMP ASSEMBLY
S6D102E
S6D102E