Information injection-pump assembly
BOSCH
9 400 616 016
9400616016
ZEXEL
101692-1441
1016921441
MITSUBISHI
ME088285
me088285
Rating:
Service parts 101692-1441 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME080082
12.
Open Pre:MPa(Kqf/cm2)
17.2{175}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 616 016
9400616016
ZEXEL
101692-1441
1016921441
MITSUBISHI
ME088285
me088285
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
Overflow valve
131424-5620
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)
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
3.5
3.45
3.55
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
9.5
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
66.2
65.2
67.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.4+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
9.3
8
10.6
Max. variation between cylinders
%
0
-14
14
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.
Injection quantity adjustment_03
Adjusting point
D
Rack position
12.4+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
70
70
75
Fixing the lever
*
Rack limit
*
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)At shipping
(5)Rack difference between N = N1 and N = N2
(6)Main spring setting
(7)Set idle sub-spring
----------
K=12 N1=1000r/min N2=700r/min
----------
----------
K=12 N1=1000r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)At shipping
----------
----------
a=9deg+-5deg b=24deg+-5deg c=(2deg)
----------
----------
a=9deg+-5deg b=24deg+-5deg c=(2deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-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:
Lubricant Information
Certain abbreviations follow S.A.E. J754 nomenclature and some classifications follow S.A.E. J183 abbreviations. The definitions other than Caterpillar's will be of assistance in purchasing lubricants. The recommended oil viscosities can be found in the Lubricant Viscosities chart in this publication.The grease is classified by the National Lubricating Grease Institute (NLGI) based on the ASTM D217-68 Worked Penetration characteristics which are given a defined consistency number.Engine Oil (EO)
Caterpillar has an oil formulation to provide maximum performance and life in your truck engine.* Cat Engine Oil (EO)Cat Engine Oil (EO) is a lubricant that meets the performance requirements of today' newer truck engines as well as meeting the needs of earlier built truck engines. This oil has sufficient TBN and sulfated ash level to be effective in operation.This lubricating oil also meets the industry standards for both diesel and gasoline engine requirements.* Cat Diesel Engine Oil (DEO)Cat Diesel Engine Oil (DEO) may be used for current truck engines also. DEO provides the required performance for 3406B truck engines, however, it does not meet the API CE performance.Alternate Oils
Failure to follow these recommendations for CE performance oils can cause shortened engine life due to carbon deposits or excessive wear.
If an oil other than Cat oil is to be used, the following oil specifications provide selection guidelines: * API specifications CE, CE/SF, or CE/SGOil with these specifications may require shortened oil change periods as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S) and infrared analysis.Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis and the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The Caterpillar 20 times rule for TBN versus fuel sulfur is a general requirement, but it can be modified by used oil analysis. The effectiveness of an oil formulation will depend on the additive package. A balanced additive package oil of a lower TBN can be as effective in fuel sulfur neutralization and overall performance as some oils with higher TBN values which have additives just for increased TBN. The used oil analysis can show these results.Consult the EMA Lubricating Oils Data Book, form SEBU6310 for a listing of oil brands meeting the CE requirements.For more information on oil and fuel sulfur content, refer to "Oil and Your Engine," form SEBD0640.Always consult with your Caterpillar dealer for the latest lubrication recommendations.Anti-Seize Compound (ASC)
Use 5P3931 Anti-Seize Compound (ASC) or equivalent.Cat Lubricating Grease
Caterpillar has greases for all applications.* Cat Multipurpose Lithium Grease (MPGL) (non-extreme pressure)This NLGI No. 2 grade is recommended for light duty automotive type applications where a high temperature [up to 175°C (350°F)] is required. This grease offers excellent mechanical stability, high resistance to oxidation, good rust protection and excellent breakaway torque.If this grease is not available, use a similar multipurpose grease.* Cat
Certain abbreviations follow S.A.E. J754 nomenclature and some classifications follow S.A.E. J183 abbreviations. The definitions other than Caterpillar's will be of assistance in purchasing lubricants. The recommended oil viscosities can be found in the Lubricant Viscosities chart in this publication.The grease is classified by the National Lubricating Grease Institute (NLGI) based on the ASTM D217-68 Worked Penetration characteristics which are given a defined consistency number.Engine Oil (EO)
Caterpillar has an oil formulation to provide maximum performance and life in your truck engine.* Cat Engine Oil (EO)Cat Engine Oil (EO) is a lubricant that meets the performance requirements of today' newer truck engines as well as meeting the needs of earlier built truck engines. This oil has sufficient TBN and sulfated ash level to be effective in operation.This lubricating oil also meets the industry standards for both diesel and gasoline engine requirements.* Cat Diesel Engine Oil (DEO)Cat Diesel Engine Oil (DEO) may be used for current truck engines also. DEO provides the required performance for 3406B truck engines, however, it does not meet the API CE performance.Alternate Oils
Failure to follow these recommendations for CE performance oils can cause shortened engine life due to carbon deposits or excessive wear.
If an oil other than Cat oil is to be used, the following oil specifications provide selection guidelines: * API specifications CE, CE/SF, or CE/SGOil with these specifications may require shortened oil change periods as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S) and infrared analysis.Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the Infrared Analysis and the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The Caterpillar 20 times rule for TBN versus fuel sulfur is a general requirement, but it can be modified by used oil analysis. The effectiveness of an oil formulation will depend on the additive package. A balanced additive package oil of a lower TBN can be as effective in fuel sulfur neutralization and overall performance as some oils with higher TBN values which have additives just for increased TBN. The used oil analysis can show these results.Consult the EMA Lubricating Oils Data Book, form SEBU6310 for a listing of oil brands meeting the CE requirements.For more information on oil and fuel sulfur content, refer to "Oil and Your Engine," form SEBD0640.Always consult with your Caterpillar dealer for the latest lubrication recommendations.Anti-Seize Compound (ASC)
Use 5P3931 Anti-Seize Compound (ASC) or equivalent.Cat Lubricating Grease
Caterpillar has greases for all applications.* Cat Multipurpose Lithium Grease (MPGL) (non-extreme pressure)This NLGI No. 2 grade is recommended for light duty automotive type applications where a high temperature [up to 175°C (350°F)] is required. This grease offers excellent mechanical stability, high resistance to oxidation, good rust protection and excellent breakaway torque.If this grease is not available, use a similar multipurpose grease.* Cat