Information injection-pump assembly
ZEXEL
101401-1711
1014011711
Rating:
Service parts 101401-1711 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME016655
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-1711
1014011711
Zexel num
Bosch num
Firm num
Name
101401-1711
INJECTION-PUMP ASSEMBLY
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
3.5
3.45
3.55
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
Pump speed
r/min
1010
1010
1010
Average injection quantity
mm3/st.
68.5
67.5
69.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.6+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
8.5
7.2
9.8
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.
135
135
140
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
2.5
2
3
Timer adjustment_02
Pump speed
r/min
350
Advance angle
deg.
2.5
2
3
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
500
Advance angle
deg.
0
0
0
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Torque spring does not operate.
(4)RACK LIMIT
(5)Rack difference between N = N1 and N = N2
(6)Main spring setting
(7)Set idle sub-spring
----------
K=12 N1=1010r/miin N2=600r/min
----------
----------
K=12 N1=1010r/miin N2=600r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=20deg+-5deg
----------
----------
a=3deg+-5deg b=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
(2)-
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-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=12deg
----------
a=(130deg)
----------
aa=12deg
----------
a=(130deg)
Information:
ACTION REQUIRED
****Parts Stock ****
Remove all 345-2985 nozzles from dealer parts stock.
Rework the following engines in dealer parts stock and/or dealer exchange inventory:
250-7100, 281-6501, 314-2485, 360-1646, 365-9318, 365-9319, 365-9320, 365-9321, and 381-8006 Service Replacement C175-16 Engines with a B7B prefix
Rework the following engines: B7B001-700.
288-8962, 314-2486, 365-9324, and 365-9325 Service Replacement C175-16 Engines with a JTL prefix
Rework the following engines: JTL001-276.
262-1300, 282-2060, 360-1647, 365-9326, 365-9327, 365-9328, and 365-9329 Service Replacement C175-20 Engines with a LLM prefix
Rework the following engines: LLM001-407.
For engines in dealer parts stock and/or dealer exchange inventory, refer to the Action Required for the Affected Product.
****Affected Product****
1. Remove the 345-2985 Ether Nozzles and supply lines on the left and right intake manifolds. If the 345-2985 Ether Nozzles are found to be broken, ensure all pieces are removed prior to putting the engine back in service.
2. Install the 8T-6764 Plug in each intake manifold.
3. Install a 6V-9829 Cap and 6V-8397 O-ring to plug both ether supply lines.
4. Disable ether injection with Cat ET (Electronic Technican).
Refer to Image1 for the location of the plug and cap on the right hand side of a 16 cylinder engine.
Refer to Image2 for the location of the plug and cap on the right hand side of a 20 cylinder engine.
Image1
Image2
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all parts removed from dealer parts stock. The parts listed in the Parts Needed will be allowed for each engine that is reworked. 1 hour labor will be allowed for each engine that is reworked. Include the engine serial numbers and arrangement numbers in the service claim story.
****Affected Product****
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 1.0-hour job
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REMOVING THE ETHER NOZZLES ON CERTAIN 793F, 793F XQ, 795F, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS
MODELS INVOLVED - 793F, 793F XQ, 795F, 797F, 797F XQ
Dear Caterpillar Product Owner:
The ether nozzles need to be replaced with a plug and have the supply lines capped off. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 01Mar2012 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 01Mar2012 Service Letter
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Group cross 101401-1711 ZEXEL
101401-1711
INJECTION-PUMP ASSEMBLY