Information injection-pump assembly
BOSCH
9 400 610 218
9400610218
ZEXEL
101692-3430
1016923430
KOMATSU
6207711360
6207711360

Rating:
Service parts 101692-3430 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6207-11-3100
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 218
9400610218
ZEXEL
101692-3430
1016923430
KOMATSU
6207711360
6207711360
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
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
3.6
3.55
3.65
Rack position
Point A R=A
Point A 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
11.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
45.1
44.1
46.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.5+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK CAP: R1
(3)The torque control spring must does not have a set force.
(4)Rack difference between N = N1 and N = N2
----------
K=4 R1=(17.5)mm N1=1100r/min N2=700r/min
----------
----------
K=4 R1=(17.5)mm N1=1100r/min N2=700r/min
----------
Speed control lever angle

F:Full speed
I:Idle
S:Stop
----------
----------
a=8deg+-5deg b=32deg+-3deg c=34deg+-5deg
----------
----------
a=8deg+-5deg b=32deg+-3deg c=34deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
(5)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
Coolant Water
The minerals (calcium and magnesium) in hard water can combine with cooling system conditioner additives (silicates and phosphates) to drop out of solution and collect inside the radiator.The minerals (silicates, phosphates, calcium and magnesium) can also accumulate onto hot engine surfaces and reduce the effectiveness of the cooling system, especially after a number of heating and cooling cycles.Distilled water is recommended because of less mineral drop out (potential or severity) than hard or tap water. Tap water, artificially softened with salt, is not recommended for use in your engine's cooling system. Use water that meets the minimum acceptable water requirement to prevent drop-out of these chemical compounds.To determine your water characteristics, contact the local water department, agricultural agent or an independent laboratory to perform the testing service.Antifreeze
Caterpillar recommends that the coolant mix contain a minimum of 30% Caterpillar Antifreeze, or equivalent and acceptable water to maintain an adequate cavitation temperature for efficient water pump performance.Premix coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted antifreeze will freeze at -10°F (-23°C).Only use a greater concentration (above 30%) of Caterpillar Antifreeze as needed for anticipated outside (ambient) temperatures. Do not exceed a coolant mixture of 60% antifreeze to water since a concentration above 60% antifreeze will reduce the engine's freeze protection and increase the possibility of deposit formation in the cooling system.
Use Caterpillar Antifreeze or ASTM D4985-89 (GM Specification 6038-M) Antifreeze. Caterpillar Antifreeze is available through your Caterpillar dealer in quantities that follow. Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. Caterpillar Antifreeze is formulated with a low silicate content and the proper coolant additives for heavy duty diesel engines. Caterpillar does not recommend use of high silicate antifreeze in the 3176 engine.ASTM D4985-89 (GM Specification 6038-M) is a low silicate antifreeze, but supplemental coolant additive must be added. Make proper antifreeze additions.Adding pure antifreeze as a makeup solution for cooling system top-off is an unacceptable practice. It increases the concentration of antifreeze in the cooling system which increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. Add antifreeze mixed with acceptable water to the same freeze protection as your cooling system. Use the chart below to assist in determining the concentration of antifreeze to use. Check the coolant solution frequently in cold weather for glycol concentration with the 5P0957 or 5P3514 Coolant Tester to ensure adequate protection. Both testers are identical except temperature scale. They give immediate, accurate readings and can be used for antifreeze/coolants that contain ethylene or propylene glycol. Both are available at your Caterpillar dealer.If propylene glycol based antifreeze is used, DO NOT allow concentration greater than a 50/50 antifreeze to water mixture. The measurement of freeze protection must be made with a refractive-type tester (5P0957 or 5P3514) rather than a hydrometer-type, which can be used to test ethylene glycol based antifreeze.Supplemental Coolant Additive (Conditioner)
Supplemental coolant additive (conditioner) is necessary to prevent rust, scale, pitting and/or corrosion
The minerals (calcium and magnesium) in hard water can combine with cooling system conditioner additives (silicates and phosphates) to drop out of solution and collect inside the radiator.The minerals (silicates, phosphates, calcium and magnesium) can also accumulate onto hot engine surfaces and reduce the effectiveness of the cooling system, especially after a number of heating and cooling cycles.Distilled water is recommended because of less mineral drop out (potential or severity) than hard or tap water. Tap water, artificially softened with salt, is not recommended for use in your engine's cooling system. Use water that meets the minimum acceptable water requirement to prevent drop-out of these chemical compounds.To determine your water characteristics, contact the local water department, agricultural agent or an independent laboratory to perform the testing service.Antifreeze
Caterpillar recommends that the coolant mix contain a minimum of 30% Caterpillar Antifreeze, or equivalent and acceptable water to maintain an adequate cavitation temperature for efficient water pump performance.Premix coolant solution to provide protection to the lowest expected outside (ambient) temperature. Pure undiluted antifreeze will freeze at -10°F (-23°C).Only use a greater concentration (above 30%) of Caterpillar Antifreeze as needed for anticipated outside (ambient) temperatures. Do not exceed a coolant mixture of 60% antifreeze to water since a concentration above 60% antifreeze will reduce the engine's freeze protection and increase the possibility of deposit formation in the cooling system.
Use Caterpillar Antifreeze or ASTM D4985-89 (GM Specification 6038-M) Antifreeze. Caterpillar Antifreeze is available through your Caterpillar dealer in quantities that follow. Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. Caterpillar Antifreeze is formulated with a low silicate content and the proper coolant additives for heavy duty diesel engines. Caterpillar does not recommend use of high silicate antifreeze in the 3176 engine.ASTM D4985-89 (GM Specification 6038-M) is a low silicate antifreeze, but supplemental coolant additive must be added. Make proper antifreeze additions.Adding pure antifreeze as a makeup solution for cooling system top-off is an unacceptable practice. It increases the concentration of antifreeze in the cooling system which increases the concentration of dissolved solids and undissolved chemical inhibitors in the cooling system. Add antifreeze mixed with acceptable water to the same freeze protection as your cooling system. Use the chart below to assist in determining the concentration of antifreeze to use. Check the coolant solution frequently in cold weather for glycol concentration with the 5P0957 or 5P3514 Coolant Tester to ensure adequate protection. Both testers are identical except temperature scale. They give immediate, accurate readings and can be used for antifreeze/coolants that contain ethylene or propylene glycol. Both are available at your Caterpillar dealer.If propylene glycol based antifreeze is used, DO NOT allow concentration greater than a 50/50 antifreeze to water mixture. The measurement of freeze protection must be made with a refractive-type tester (5P0957 or 5P3514) rather than a hydrometer-type, which can be used to test ethylene glycol based antifreeze.Supplemental Coolant Additive (Conditioner)
Supplemental coolant additive (conditioner) is necessary to prevent rust, scale, pitting and/or corrosion