Information injection-pump assembly
BOSCH
9 400 612 172
9400612172
ZEXEL
101609-3600
1016093600
Rating:
Service parts 101609-3600 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
4063212
12.
Open Pre:MPa(Kqf/cm2)
22.0{224}
15.
NOZZLE SET
Include in #1:
101609-3600
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 172
9400612172
ZEXEL
101609-3600
1016093600
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
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
2.7
2.65
2.75
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
10.1
Pump speed
r/min
975
975
975
Average injection quantity
mm3/st.
110
109
111
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
38.7
38.7
Boost pressure
mmHg
290
290
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.7+-0.5
Pump speed
r/min
525
525
525
Average injection quantity
mm3/st.
9.5
8.5
10.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
10.3++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
85
95
Fixing the lever
*
Boost pressure
kPa
38.7
38.7
Boost pressure
mmHg
290
290
Rack limit
*
Injection quantity adjustment_04
Adjusting point
E
Rack position
9.4
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
50
45
55
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
850
850
850
Rack position
9.4
Boost pressure
kPa
10
8.7
11.3
Boost pressure
mmHg
75
65
85
Boost compensator adjustment_02
Pump speed
r/min
850
850
850
Rack position
(10.1)
Boost pressure
kPa
25.3
25.3
25.3
Boost pressure
mmHg
190
190
190
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)It is not necessary to supply hydraulic pressure because the specification is for the hydraulic ACT normally ON.
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
----------
K=13 BCL=(0.7)mm
----------
----------
K=13 BCL=(0.7)mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Rack position = aa, speed = bb
(2)Stopper bolt setting
----------
aa=1-0.5mm bb=0r/min
----------
a=26deg+-5deg b=7deg+-5deg c=31deg+-3deg
----------
aa=1-0.5mm bb=0r/min
----------
a=26deg+-5deg b=7deg+-5deg c=31deg+-3deg
0000001501 I/P WITH LOAD PLUNGER ADJ
Adjusting procedure for load plunger equipped pump with RSV (cam lock) governor (see service information S.I. 434 for details).
At cam lift h+-0.01, set the camshaft c deg from the * mark in accordance with the timing adjustment procedure.
2. Align the flyweight's timing tooth position and the lock pin groove and then fully tighten the flyweight to the camshaft. Then, remove the lock pin.
3. Adjust the maximum variation between cylinders and injection quantity.
4. Adjust using the pre-stroke adjusting shim so that the pre-stroke value is the value for 4/4 load (standard point A).
5. After adjusting the pre-stroke, reconfirm that the injection quantity and the maximum variation between cylinders are as specified.
6. At delivery, again fix the flyweight using the lock pin.
----------
h=2.7mm c=5deg30min+-30min
----------
----------
h=2.7mm c=5deg30min+-30min
----------
Timing setting
(1)Pump vertical direction
(2)Key groove position for No. 1 cylinder's cam lift h = cc (at BTDC aa).
(3)Key groove position for No. 1 cylinder's beginning of injection (at point A after injection quantity adjustment).
(4)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).
(5)B.T.D.C.: aa
----------
aa=11deg bb=0deg cc=2.7+-0.01mm
----------
a=55deg48min+-3deg b=55deg48min+-3deg13min48sec c=5deg30min+-30min
----------
aa=11deg bb=0deg cc=2.7+-0.01mm
----------
a=55deg48min+-3deg b=55deg48min+-3deg13min48sec c=5deg30min+-30min
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
July 31, 1996Problem
0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 need to be removed from Parts Stock.Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 01, 1995 at plant number 068).
Action Required Cont.
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
TEPS/MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 removed from Parts Stock.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".
Termination Date
July 31, 1996Problem
0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 need to be removed from Parts Stock.Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 01, 1995 at plant number 068).
Action Required Cont.
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
TEPS/MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 removed from Parts Stock.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors with date codes prior to January 01, 1996 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".