101609-9010 ZEXEL 9 400 611 265 BOSCH INJECTION-PUMP ASSEMBLY 9400611265 1016099010 3436105051

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 265 9400611265

ZEXEL 101609-9010 1016099010

MITSUBISHI-HEAV 3436105051 3436105051

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Buy INJECTION-PUMP ASSEMBLY 101609-9010 zexel genuine, new aftermarket engine parts with delivery

Service parts 101609-9010 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8380

3. GOVERNOR 105419-3991

4. SUPPLY PUMP

105220-7180

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6760

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3330

14. NOZZLE

105017-2760

15. NOZZLE SET

Include in #1:

101609-9010 as INJECTION-PUMP ASSEMBLY

Include in #2:

104268-1240 as _

Cross reference number

BOSCH 9 400 611 265 9400611265

ZEXEL 101609-9010 1016099010

MITSUBISHI-HEAV 3436105051 3436105051

Zexel num

Bosch num

Firm num

Name

101609-9010

9 400 611 265

3436105051 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S6K-T K

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-5720

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8.8

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 98 97 99

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.8+-0.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 96 92 100

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 6+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_04

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 95 100

Fixing the lever *

Rack limit *

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)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2
----------
K=16 N1=850r/min N2=400r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Stopper bolt setting
----------

----------
a=2deg+-5deg b=33deg+-3deg c=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, speed = bb. (2)Normal
----------
aa=1-0.5mm bb=0r/min
----------
a=21deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

April 19, 2004
U-118
A-80
D-95
O-98
TT-10
TA-1
TM-3
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN REMANUFCTURED FUEL INJECTORS FROM DEALER PARTS STOCK
7750 PI70077
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
July 31, 2004PROBLEM
The injector nose cone may be undersize on certainremanufactured fuel injectors that are used in various 3116 Engines. All0R8461, 0R8463, 0R8465, 0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483,0R8633, 0R8682, 0R8684, and 0R8867 Remanufactured Fuel Injectors with DateCodes from 01/02/04 to 31/03/04 stamped on the box need to be removed fromdealer stock.ACTION REQUIRED
Remove all Remanufactured Fuel Injectors listedin the following chart from dealer parts stock that have Date Codes from01/02/04 to 31/03/04 stamped on the box.
Part Number Description Box Date Code
0R8461 INJECTOR GP 01/02/04 to 31/03/04
0R8463 INJECTOR GP 01/02/04 to 31/03/04
0R8465 INJECTOR GP 01/02/04 to 31/03/04
0R8469 INJECTOR GP 01/02/04 to 31/03/04
0R8471 INJECTOR GP 01/02/04 to 31/03/04
0R8473 INJECTOR GP 01/02/04 to 31/03/04
0R8475 INJECTOR GP 01/02/04 to 31/03/04
0R8479 INJECTOR GP 01/02/04 to 31/03/04
0R8483 INJECTOR GP 01/02/04 to 31/03/04
0R8633 INJECTOR GP 01/02/04 to 31/03/04
0R8682 INJECTOR GP 01/02/04 to 31/03/04
0R8684 INJECTOR GP 01/02/04 to 31/03/04
0R8867 INJECTOR GP 01/02/04 to 31/03/04
SERVICE CLAIM ALLOWANCES
Submit one claim for all 0R8461, 0R8463, 0R8465,0R8469, 0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684,and 0R8867 Remanufactured Fuel Injectors that were removed from dealerparts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70077.***** All Dealers *****Return all 0R8461, 0R8463, 0R8465, 0R8469,0R8471, 0R8473, 0R8475, 0R8479, 0R8483, 0R8633, 0R8682, 0R8684, and 0R8867Remanufactured Fuel Injectors that are removed from parts stock and a copyof the claim to:Caterpillar Inc.
Attn: Noe S. Perez - PI70077
Service Claims Room
8201 N. University
Peoria, IL 61615