Information injection-pump assembly
BOSCH
9 400 612 896
9400612896
ZEXEL
108622-3094
1086223094
HINO
220007555B
220007555b
Rating:
Service parts 108622-3094 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-2391B
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/27.5{280}
14.
NOZZLE
Include in #1:
108622-3094
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 896
9400612896
ZEXEL
108622-3094
1086223094
HINO
220007555B
220007555b
Zexel num
Bosch num
Firm num
Name
9 400 612 896
220007555B HINO
INJECTION-PUMP ASSEMBLY
P-4 * K 14CJ TICS HD-TI6M TICS
P-4 * K 14CJ TICS HD-TI6M TICS
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-1520
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
21
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
1-4-2-6-
3-5
Pre-stroke
mm
6.4
6.37
6.43
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.8
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
193.4
191.4
195.4
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
64
64
Boost pressure
mmHg
480
480
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.2
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
168.6
165.6
171.6
Fixing the lever
*
Boost pressure
kPa
64
64
Boost pressure
mmHg
480
480
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_03
Adjusting point
C
Rack position
9.05
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
138.2
135.2
141.2
Fixing the lever
*
Boost pressure
kPa
64
64
Boost pressure
mmHg
480
480
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
220
215
225
Fixing the lever
*
Boost pressure
kPa
64
64
Boost pressure
mmHg
480
480
Rack limit
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_05
Adjusting point
E
Rack position
4+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
12.5
9.5
15.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_06
Adjusting point
G
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
129
129
169
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_07
Adjusting point
H
Rack position
10.8+-0.
5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
192.1
186.1
198.1
Fixing the lever
*
Boost pressure
kPa
64
64
Boost pressure
mmHg
480
480
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
8.15
Boost pressure
kPa
22
20
22
Boost pressure
mmHg
165
150
165
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
10.8
Boost pressure
kPa
50.7
50.7
50.7
Boost pressure
mmHg
380
380
380
0000001601
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
5
4.5
5.5
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
4
3.95
4.05
Output voltage
V
2.62
2.61
2.63
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
6.4
6.37
6.43
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_05
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
3.4
Output voltage
V
3
2.98
3
Confirmation
*
_06
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Stop lever setting: R1
(5)RACK LIMIT
(6)Boost compensator stroke: BCL
(7)Damper spring setting
----------
RT=1 TH=2.8mm R1=12.4+0.2mm BCL=2.65+-0.1mm
----------
----------
RT=1 TH=2.8mm R1=12.4+0.2mm BCL=2.65+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=11deg+-5deg
----------
----------
a=11deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=45mm
----------
a=25deg+-5deg b=39.5deg+-3deg
----------
aa=45mm
----------
a=25deg+-5deg b=39.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set stopper screw so that rack position = aa (after setting, apply red paint).
(2)Use the hole at R = bb
----------
aa=12.4+0.2mm bb=33mm
----------
a=30deg+-5deg b=42deg+-5deg
----------
aa=12.4+0.2mm bb=33mm
----------
a=30deg+-5deg b=42deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=6.4+-0.03mm
----------
a=(40deg)
----------
aa=6.4+-0.03mm
----------
a=(40deg)
0000001901
(A): Pre-stroke actuator
(B): Stamp housings A and B at the same time.
(C): Stamping range
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
Adjustment of the rack sensor (-0720)
1. Rack limit adjustment
(1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position.
(2)Install the rod (E) to the block (C).
(3)At the rack limit, set the distance between the pump end face and the rod (E) to L1.
2. Rack sensor
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side and set the pump speed at N1.
(3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join. Output voltage VR +-0.01(V), speed N1, rack position Ra, rack sensor supply voltage 5+-0.01 (V)
----------
L=33.5+-0.1mm N1=550r/min Ra=10.8mm
----------
----------
L=33.5+-0.1mm N1=550r/min Ra=10.8mm
----------
Information:
Caterpillar: Confidential Yellow
OPTIONAL:IMPROVED FUEL TRANSFER PUMP SEALS FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE - 3406B IN ALL APP LICATIONS - PI7090 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, TRUCK, MARINE & AGRICULTURE TEPS
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
IMPROVED FUEL TRANSFER PUMP VALVES FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE, 3406B Truck, Marine, And Industrial Engines; 3406B Generator Sets; 16G Motor Graders; 245 Excavators And Front Shovels; 824C Tractors; 825C, 826C Compactors; 980C Loaders, 1254, 1256, 1250, PI7090 U-56 A-36 AU-47 B-21 C-51 E-34 O-42 TT-3 TA-3 TM-4 optional parts stock action needed If you received the January 6, 1984 Safety Service Letter (PI1019) and/or the December 2, 1983 Service Letter (PI7049), do all three PIP's at the same time. Problems ****Transfer Pump Valves**** The fuel transfer pump on the above engines has three 1W6182 Valve Assemblies. The one valve in the piston can break in extremely cold weather due to excessive restriction from jelled fuel. Some damage can also occur to the other valve assemblies. A new valve with less flow restriction is now used in the piston and at the other two locations in the pump. These valves are directly adaptable to earlier engines. ****Combustion Gas Leakage Around Fuel Nozzles**** There is a possibility that combustion gases can escape by a fuel injection nozzle and into the adapter. The high temperatures soften the end of the nozzle body and cause the tip to come off. The usual cause for escaping combustion gases is either a loose nozzle in the adapter or a cut in the carbon dam (gas seal). See Illustration 1. Nozzle hold down clamps are all now tightened properly, and an improved chamfer is machined inside the bottom of the adapters to prevent cutting the carbon dam. ILLUSTRATION 1 (SEE ILLUSTRATION) Affected Models And Parts Needed Some of the following vehicles contain the 3406 Engine with the former scroll fuel system and are not in this Program. PIN's (Product Identification No.) Or Serial No. Model Both Problems Gas Leakage Only 3406B Truck Engine 7FB1-8348 8349 - 10145 3406B Marine Engine 4TB1-383 384 - 396 3406B Industrial Engine 6TB1-1184 1185 - 1276 3406B Generator Set 2WB1-1044 1045 - 1166 16G Motor Grader 93U2284-93U2417 93U2418-93U2432 245 Excavator 95V1084-95V1111 95V1112-95V1116 245 Excavator
OPTIONAL:IMPROVED FUEL TRANSFER PUMP SEALS FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE - 3406B IN ALL APP LICATIONS - PI7090 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, TRUCK, MARINE & AGRICULTURE TEPS
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
IMPROVED FUEL TRANSFER PUMP VALVES FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE, 3406B Truck, Marine, And Industrial Engines; 3406B Generator Sets; 16G Motor Graders; 245 Excavators And Front Shovels; 824C Tractors; 825C, 826C Compactors; 980C Loaders, 1254, 1256, 1250, PI7090 U-56 A-36 AU-47 B-21 C-51 E-34 O-42 TT-3 TA-3 TM-4 optional parts stock action needed If you received the January 6, 1984 Safety Service Letter (PI1019) and/or the December 2, 1983 Service Letter (PI7049), do all three PIP's at the same time. Problems ****Transfer Pump Valves**** The fuel transfer pump on the above engines has three 1W6182 Valve Assemblies. The one valve in the piston can break in extremely cold weather due to excessive restriction from jelled fuel. Some damage can also occur to the other valve assemblies. A new valve with less flow restriction is now used in the piston and at the other two locations in the pump. These valves are directly adaptable to earlier engines. ****Combustion Gas Leakage Around Fuel Nozzles**** There is a possibility that combustion gases can escape by a fuel injection nozzle and into the adapter. The high temperatures soften the end of the nozzle body and cause the tip to come off. The usual cause for escaping combustion gases is either a loose nozzle in the adapter or a cut in the carbon dam (gas seal). See Illustration 1. Nozzle hold down clamps are all now tightened properly, and an improved chamfer is machined inside the bottom of the adapters to prevent cutting the carbon dam. ILLUSTRATION 1 (SEE ILLUSTRATION) Affected Models And Parts Needed Some of the following vehicles contain the 3406 Engine with the former scroll fuel system and are not in this Program. PIN's (Product Identification No.) Or Serial No. Model Both Problems Gas Leakage Only 3406B Truck Engine 7FB1-8348 8349 - 10145 3406B Marine Engine 4TB1-383 384 - 396 3406B Industrial Engine 6TB1-1184 1185 - 1276 3406B Generator Set 2WB1-1044 1045 - 1166 16G Motor Grader 93U2284-93U2417 93U2418-93U2432 245 Excavator 95V1084-95V1111 95V1112-95V1116 245 Excavator