Information injection-pump assembly
BOSCH
9 400 611 616
9400611616
ZEXEL
103672-0370
1036720370
NIIGATA-URAWA
74V47021A
74v47021a
Rating:
Service parts 103672-0370 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
12.7{130}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 611 616
9400611616
ZEXEL
103672-0370
1036720370
NIIGATA-URAWA
74V47021A
74v47021a
Zexel num
Bosch num
Firm num
Name
9 400 611 616
74V47021A NIIGATA-URAWA
INJECTION-PUMP ASSEMBLY
6NSD * K 14BS PE4-8Z PE
6NSD * K 14BS PE4-8Z PE
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500
Outer diameter - inner diameter - length (mm) mm 8-4-1500
Overflow valve
131425-0120
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
6-3-5-1-
4-2
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 6-3 deg. 60 59.5 60.5
Cal 6-3 deg. 60 59.5 60.5
Difference between angles 2
Cal 6-5 deg. 120 119.5 120.5
Cal 6-5 deg. 120 119.5 120.5
Difference between angles 3
Cal 6-1 deg. 180 179.5 180.5
Cal 6-1 deg. 180 179.5 180.5
Difference between angles 4
Cal 6-4 deg. 240 239.5 240.5
Cal 6-4 deg. 240 239.5 240.5
Difference between angles 5
Cal 6-2 deg. 300 299.5 300.5
Cal 6-2 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
14.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
479
464
494
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.7+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
41.5
38
45
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
5.1+-0.5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
21.8
18.3
25.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Delivered with idle spring not operating.
(3)RACK LIMIT: RAL
(4)Idle sub spring setting: L1.
----------
K=17 RAL=16.3+0.5mm L1=6.2-0.5mm
----------
----------
K=17 RAL=16.3+0.5mm L1=6.2-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Actual measurement
(2)Actual measurement
(3)Stopper bolt setting
(4)Pump speed = aa
(5)Speed = bb (at shipping)
----------
aa=600r/min bb=630r/min
----------
a=2deg+-5deg
----------
aa=600r/min bb=630r/min
----------
a=2deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=35deg+-5deg b=10deg+-5deg
----------
----------
a=35deg+-5deg b=10deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Center of pump side coupling's elongated hole at No. 6 cylinder's beginning of injection.
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
FACE="Courier New">CONFIDENTIAL
TECHNICAL INFORMATION BULLETIN March 27, 2002
Engines 3516 (25Z, 5SJ, 7KM, CMD, 4XF)
3516B (1HZ, 7RN, 5AN, FDN, BDP,
6HN)
Component Code: 1404SUBJECT: Generator Stator Adapter Cracking on 3516 Diesel Generator Set
PROBLEM:
Certain SR4B single bearing generators may develop cracks in the adapter assembly. The generator adapter is the welded assembly, part of the generator stator, consisting of the front adapter ring that bolts to the flywheel housing and the individual support bars welded to this adapter ring. Several different weld failure modes exist for the generator adapter. First, there may be cracks along the top weld leg between the adapter supports and the front adapter ring. Second, there may be cracks at the toe of the welds joining the adapter support bars to the front ring. These cracks appear in the heat-affected zone of the welds and propagate into the front adapter ring of the generator. The third failure mode is radial cracks between the end ring of the generator adapter and the stator housing. This type of crack most likely occurs after the support welds have failed. After the support welds have failed, the cracks at the toe of the support bars propagate into the ring and create a stress riser.
SOLUTION:
Caterpillar is redesigning the current product and is also working on a solution that will address the existing units in the field. At this time, it is NOT recommended to immediately replace cracked generator stators, nor is it recommended to re-weld the cracked adapters as a field repair. Rather, a crack observation and evaluation process should be established for each individual case. It is anticipated that the first recognizable cracks on suspect generators (cracks size of 0.25" and larger) may appear as early as 300 hours. If any of the above-described cracks are found, the servicing dealer should contact Caterpillar Service. The servicing dealer should also assist in periodic inspection of the cracks in an effort to determine the next action.
Contact (if different from sender): Miro Halicek (770) 233-5877 or Marc Sylvester (770) 233-5630.
COPYRIGHT 2002 CATERPILLAR
ALL RIGHTS RESERVED
TECHNICAL INFORMATION BULLETIN March 27, 2002
Engines 3516 (25Z, 5SJ, 7KM, CMD, 4XF)
3516B (1HZ, 7RN, 5AN, FDN, BDP,
6HN)
Component Code: 1404SUBJECT: Generator Stator Adapter Cracking on 3516 Diesel Generator Set
PROBLEM:
Certain SR4B single bearing generators may develop cracks in the adapter assembly. The generator adapter is the welded assembly, part of the generator stator, consisting of the front adapter ring that bolts to the flywheel housing and the individual support bars welded to this adapter ring. Several different weld failure modes exist for the generator adapter. First, there may be cracks along the top weld leg between the adapter supports and the front adapter ring. Second, there may be cracks at the toe of the welds joining the adapter support bars to the front ring. These cracks appear in the heat-affected zone of the welds and propagate into the front adapter ring of the generator. The third failure mode is radial cracks between the end ring of the generator adapter and the stator housing. This type of crack most likely occurs after the support welds have failed. After the support welds have failed, the cracks at the toe of the support bars propagate into the ring and create a stress riser.
SOLUTION:
Caterpillar is redesigning the current product and is also working on a solution that will address the existing units in the field. At this time, it is NOT recommended to immediately replace cracked generator stators, nor is it recommended to re-weld the cracked adapters as a field repair. Rather, a crack observation and evaluation process should be established for each individual case. It is anticipated that the first recognizable cracks on suspect generators (cracks size of 0.25" and larger) may appear as early as 300 hours. If any of the above-described cracks are found, the servicing dealer should contact Caterpillar Service. The servicing dealer should also assist in periodic inspection of the cracks in an effort to determine the next action.
Contact (if different from sender): Miro Halicek (770) 233-5877 or Marc Sylvester (770) 233-5630.
COPYRIGHT 2002 CATERPILLAR
ALL RIGHTS RESERVED