Information injection-pump assembly
BOSCH
9 400 616 041
9400616041
ZEXEL
101692-3601
1016923601
KOMATSU
6206711930
6206711930
Rating:
Service parts 101692-3601 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 616 041
9400616041
ZEXEL
101692-3601
1016923601
KOMATSU
6206711930
6206711930
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
10.4
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
36.5
35.5
37.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
10.5+-0.
5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.5
9.5
11.5
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)Rack difference between N = N1 and N = N2
----------
K=15 R1=(17.5)mm N1=1350r/min N2=750r/min
----------
----------
K=15 R1=(17.5)mm N1=1350r/min N2=750r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=24deg+-5deg b=17deg+-5deg c=32deg+-3deg
----------
----------
a=24deg+-5deg b=17deg+-5deg c=32deg+-3deg
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:
3114 ATAAC Engine Model Views
Oil Filter (1), Fan Pulley & Bearing Assembly (2), Thermostat Housing (3), Alternator (4), Turbocharger (5), Electric Starting Motor (6), Crankshaft Pulley (7), Water Pump (8), Oil Level Gage (Dipstick) (9), Oil Drain Plug (10), Fuel Transfer Pump and Governor (11), Air Compressor (12), Oil Filler (13), Fuel Filter (14), Air Cleaner with Restriction Gauge (15), Lift Eye (16), Fuel Priming Pump (17), Crankcase Breather (18) and Power Steering Pump (19).3116 ATAAC Engine Model Views
LEFT SIDE VIEW
Fan Pulley & Bearing Assembly (1), Thermostat Housing (2), Crankshaft Vibration Damper & Pulley (3116 ONLY) (3), Oil Level Gage (Dipstick) (4), Oil Drain Plug (5), Fuel Transfer Pump and Governor (6), Air Compressor (7), Oil Filler (8), Fuel Filter (9), Lift Eye (10), Fuel Priming Pump (11), Crankcase Breather (12) and Power Steering Pump (13), Fuel Filter Bleed Screw (14).Engine Information
The engines described in this Manual are the 3114 and 3116 ATAAC Diesel Truck engines designed primarily for on-highway medium duty applications.3114 Engine
The Caterpillar 3114 Truck (Vehicular) Engine has a 4.4 liter (269 inch3) displacement, with 105 mm (4.13 inch) bore and 127 mm (5.0 inch) stroke. The engine is a four stroke cycle, in-line 4 cylinder with direct injection. 3116 Engine
The Caterpillar 3116 Truck (Vehicular) Engine has a 6.6 liter (403 inch3) displacement, with 105 mm (4.13 inch) bore and 127 mm (5.0 inch) stroke. The engine is a four stroke cycle, in-line 6 cylinder with direct injection. All Engines
3114 & 3116 Cylinder and Valve Location Rated speed for the Truck (Vehicular) Engine, turbocharged with Air-to-Air Aftercooling System (ATAAC), equipped with a mechanical governor and high pressure injection fuel system is 2600 rpm. Refer to the Information Plate or Caterpillar for information regarding your engine.The cooling system consists of a belt driven centrifugal pump, with a thermostat which regulates engine coolant temperature, electric fan clutch, an oil cooler and a radiator incorporating a shunt system.The engine lubricating oil (both cooled and filtered) is supplied by a gear-type pump and bypass valves provide unrestricted flow of oil to engine parts when oil viscosity is high, or if the oil cooler or filter elements become plugged.To obtain maximum efficiency and lowest cost to operate and own your Caterpillar engine, use only recommended fuels and lubricants and follow the maintenance recommendations in the Maintenance Schedule which can be found in the Maintenance Section of this Manual.Serial Number Plate and Information Plate Locations
Engine Identification
Caterpillar engines are identified with Serial Numbers, Performance Specification Numbers (fuel system settings) and Arrangement Numbers. In some cases Modification Numbers are also used. These numbers are shown on the Serial Number Plate (1) mounted on the engine.Caterpillar needs all of these numbers to determine which components were included on the engine when it was assembled at the factory. This permits accurate identification of replacement part numbers.Serial Number Plate
There are two possible locations for the Serial Number Plate (1).Some engines have the plate on the left side of the engine and some engines will have the
Oil Filter (1), Fan Pulley & Bearing Assembly (2), Thermostat Housing (3), Alternator (4), Turbocharger (5), Electric Starting Motor (6), Crankshaft Pulley (7), Water Pump (8), Oil Level Gage (Dipstick) (9), Oil Drain Plug (10), Fuel Transfer Pump and Governor (11), Air Compressor (12), Oil Filler (13), Fuel Filter (14), Air Cleaner with Restriction Gauge (15), Lift Eye (16), Fuel Priming Pump (17), Crankcase Breather (18) and Power Steering Pump (19).3116 ATAAC Engine Model Views
LEFT SIDE VIEW
Fan Pulley & Bearing Assembly (1), Thermostat Housing (2), Crankshaft Vibration Damper & Pulley (3116 ONLY) (3), Oil Level Gage (Dipstick) (4), Oil Drain Plug (5), Fuel Transfer Pump and Governor (6), Air Compressor (7), Oil Filler (8), Fuel Filter (9), Lift Eye (10), Fuel Priming Pump (11), Crankcase Breather (12) and Power Steering Pump (13), Fuel Filter Bleed Screw (14).Engine Information
The engines described in this Manual are the 3114 and 3116 ATAAC Diesel Truck engines designed primarily for on-highway medium duty applications.3114 Engine
The Caterpillar 3114 Truck (Vehicular) Engine has a 4.4 liter (269 inch3) displacement, with 105 mm (4.13 inch) bore and 127 mm (5.0 inch) stroke. The engine is a four stroke cycle, in-line 4 cylinder with direct injection. 3116 Engine
The Caterpillar 3116 Truck (Vehicular) Engine has a 6.6 liter (403 inch3) displacement, with 105 mm (4.13 inch) bore and 127 mm (5.0 inch) stroke. The engine is a four stroke cycle, in-line 6 cylinder with direct injection. All Engines
3114 & 3116 Cylinder and Valve Location Rated speed for the Truck (Vehicular) Engine, turbocharged with Air-to-Air Aftercooling System (ATAAC), equipped with a mechanical governor and high pressure injection fuel system is 2600 rpm. Refer to the Information Plate or Caterpillar for information regarding your engine.The cooling system consists of a belt driven centrifugal pump, with a thermostat which regulates engine coolant temperature, electric fan clutch, an oil cooler and a radiator incorporating a shunt system.The engine lubricating oil (both cooled and filtered) is supplied by a gear-type pump and bypass valves provide unrestricted flow of oil to engine parts when oil viscosity is high, or if the oil cooler or filter elements become plugged.To obtain maximum efficiency and lowest cost to operate and own your Caterpillar engine, use only recommended fuels and lubricants and follow the maintenance recommendations in the Maintenance Schedule which can be found in the Maintenance Section of this Manual.Serial Number Plate and Information Plate Locations
Engine Identification
Caterpillar engines are identified with Serial Numbers, Performance Specification Numbers (fuel system settings) and Arrangement Numbers. In some cases Modification Numbers are also used. These numbers are shown on the Serial Number Plate (1) mounted on the engine.Caterpillar needs all of these numbers to determine which components were included on the engine when it was assembled at the factory. This permits accurate identification of replacement part numbers.Serial Number Plate
There are two possible locations for the Serial Number Plate (1).Some engines have the plate on the left side of the engine and some engines will have the