Information injection-pump assembly
BOSCH
9 400 610 372
9400610372
ZEXEL
104304-4482
1043044482
ISHIKAWAJIMA-S
131017382
131017382
Rating:
Service parts 104304-4482 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
4.
SUPPLY PUMP
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
13140 63 80
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
104304-4482
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 610 372
9400610372
ZEXEL
104304-4482
1043044482
ISHIKAWAJIMA-S
131017382
131017382
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
1-3-4-2
Pre-stroke
mm
1.95
1.9
2
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 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
B
Rack position
8.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
34
33
35
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
4.4+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
6
5
7
Max. variation between cylinders
%
0
-14
14
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Rack difference between N = N1 and N = N2
(2)Rack difference between N = N3 and N = N4
----------
N1=1250r/min N2=400r/min N3=1250r/min N4=900r/min
----------
----------
N1=1250r/min N2=400r/min N3=1250r/min N4=900r/min
----------
Speed control lever angle
F:Full speed
I:Idle
----------
----------
a=21deg+-5deg b=25deg+-6deg
----------
----------
a=21deg+-5deg b=25deg+-6deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=(38deg)
----------
----------
a=20deg+-5deg b=(38deg)
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)
----------
----------
a=(50deg)
Information:
PARTS NEEDED
Qty
Part Number Description
2 5P4115 WASHER-HARD
2 6S8620 CLAMP-HOSE
4 8T4121 WASHER-HARD
2 8T4171 BOLT-HEX HEAD
2 8T4195 BOLT-HEX HEAD
1 3550632 CONNECTOR-SPL
1 4609257 INJECTOR AS-DEF
1 4719926 TANK AS-ALUMINUM
1 4719927 PLATE AS
2 4719928 PLATE AS
9 4721116 HOSE-BULK (9cm)
1 5218238 SFWR GP-A1000
1 BULK_COOLANT COOLANT - See Action Required
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
1. Replace the DEF Injector, As per the Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Please ensure that the coolant drained from the system is stored in a suitable storage container and not refilled until the end of the following procedure.
2. Position bracket assembly 471-9927 onto the CEM. Ensure that the bracket is correctly orientated. As per Image 1
3. Position the two 471-9928 plates onto the CEM and install 8T-4195 bolts with the 8T-4121 washers. As per Image 2
4. Position coolant tank 471-9926 onto bracket. Install bolts 8T-4171 with 5P-4115 washer. Tighten to 9 Nm. As per Image 1
5. Remove coolant supply hose 349-6234 from DEF injector and connect to tank 471-9926 inlet using existing clamp. As per Image 1
6. Connect hose assembly 472-1116 (9cm) to tank 471-9926 and the DEF injector. Secure with 2 off 6S?8620 clamps, As per Image 1
7. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, ?Cooling System Coolant - Change? for the correct procedure. If required, top up the coolant system.
8. Flash the engine ECM with the software or latest available in SIS Web.
For flash programming the engine ECM, refer to Troubleshooting, "Flash Programming".
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.