Information injection-pump assembly
BOSCH
9 400 614 311
9400614311
ZEXEL
101491-1210
1014911210
MITSUBISHI
ME080228
me080228
Rating:
Service parts 101491-1210 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 614 311
9400614311
ZEXEL
101491-1210
1014911210
MITSUBISHI
ME080228
me080228
Zexel num
Bosch num
Firm num
Name
101491-1210
9 400 614 311
ME080228 MITSUBISHI
INJECTION-PUMP ASSEMBLY
4D31T * K
4D31T * K
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
Overflow valve
131424-4620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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)
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
3.2
3.15
3.25
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
A
Rack position
9.7
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
51.2
50.2
52.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
7.5
6.2
8.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
64
64
69
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1.5
1.2
1.8
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1250
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
3
3
3
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Supplied with torque spring not set.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)At shipping
----------
K=15
----------
----------
K=15
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Rack position = aa
(2)At shipping
----------
aa=1mm
----------
a=17deg+-5deg b=(35deg) c=(2deg) d=30deg+-5deg
----------
aa=1mm
----------
a=17deg+-5deg b=(35deg) c=(2deg) d=30deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)At shipping
----------
----------
a=38deg+-5deg b=53deg+-5deg
----------
----------
a=38deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(130deg)
----------
aa=16deg
----------
a=(130deg)
Information:
If complete injector sets are replacedon 3412E machines:
PART Hours/Age, whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-4000 0-48 mos 100% 7 0 0 0 0
4001-8000 0-48 mos 33.3% 3.5 0 0 50% 3.5
* This is a 7-hour job. Actual hourspermitted up to maximums noted above.PARTS DISPOSITION
NACD Dealers, return Injector(s) to:Caterpillar Inc.Attn: Fergal O?Shea ? PS50424
Service Claims Room
8201 N. University
Peoria, IL 61615 ***** All Other Dealers *****
Handle the parts in accordance with yourWarranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.
Use "Test for Cylinder Cutout" to determine ifindividual injector replacements (using original injector part) are needed.
Use "Test for Leakage from Poppet Valve" to determineif full injector sets (using new injector parts and software change) areappropriate for repair.
Test for Cylinder Cutout:
Warm the engine out of Cold Mode.
Connect Caterpillar Electronic Technician (ET)to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm +/- 125rpm. An extremely rough running engine well need to be diagnosed by othermethods.
Cut out one bank of cylinders. Note engine rpmand the fuel position on the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
If this is the third injector failure,related to this Service Letter, and to the same engine serial number within120 calendar days, replace all the injectors and software following SpecialInstruction article REHS1385.It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from PoppetValve:
Warm engine out of Cold Mode to normal operatingtemperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
: Hot oil and components can causepersonal injury. Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port
PART Hours/Age, whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-4000 0-48 mos 100% 7 0 0 0 0
4001-8000 0-48 mos 33.3% 3.5 0 0 50% 3.5
* This is a 7-hour job. Actual hourspermitted up to maximums noted above.PARTS DISPOSITION
NACD Dealers, return Injector(s) to:Caterpillar Inc.Attn: Fergal O?Shea ? PS50424
Service Claims Room
8201 N. University
Peoria, IL 61615 ***** All Other Dealers *****
Handle the parts in accordance with yourWarranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.
Use "Test for Cylinder Cutout" to determine ifindividual injector replacements (using original injector part) are needed.
Use "Test for Leakage from Poppet Valve" to determineif full injector sets (using new injector parts and software change) areappropriate for repair.
Test for Cylinder Cutout:
Warm the engine out of Cold Mode.
Connect Caterpillar Electronic Technician (ET)to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm +/- 125rpm. An extremely rough running engine well need to be diagnosed by othermethods.
Cut out one bank of cylinders. Note engine rpmand the fuel position on the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
If this is the third injector failure,related to this Service Letter, and to the same engine serial number within120 calendar days, replace all the injectors and software following SpecialInstruction article REHS1385.It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from PoppetValve:
Warm engine out of Cold Mode to normal operatingtemperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
: Hot oil and components can causepersonal injury. Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port
Have questions with 101491-1210?
Group cross 101491-1210 ZEXEL
Mitsubishi
101491-1210
9 400 614 311
ME080228
INJECTION-PUMP ASSEMBLY
4D31T
4D31T