Information injection-pump assembly
BOSCH
9 400 619 606
9400619606
ZEXEL
101681-9441
1016819441
Rating:
Service parts 101681-9441 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
101681-9441
as INJECTION-PUMP ASSEMBLY
Include in #2:
104745-3160
as _
Cross reference number
BOSCH
9 400 619 606
9400619606
ZEXEL
101681-9441
1016819441
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
2.2
2.15
2.25
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
10.9
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
55.5
54
57
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.7+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
60.5
60.5
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
700
Advance angle
deg.
1
0.5
1.5
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
2.7
2
3.4
Timer adjustment_05
Pump speed
r/min
1400
Advance angle
deg.
4.4
3.7
5.1
Timer adjustment_06
Pump speed
r/min
1500
Advance angle
deg.
4.8
4.1
5.5
Timer adjustment_07
Pump speed
r/min
-
Advance angle
deg.
6
6
6
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Excess fuel lever setting: EXL (N = N1)
(3)Damper spring setting
(4)Rack difference between N = N2 and N = N3
----------
EXL=12.1+0.2mm N1=500r/min N2=1500r/min N3=900r/min
----------
----------
EXL=12.1+0.2mm N1=500r/min N2=1500r/min N3=900r/min
----------
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=16deg+-5deg b=29.5deg+-3deg
----------
----------
a=16deg+-5deg b=29.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=71deg+-5deg
----------
----------
a=20deg+-5deg b=71deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
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.