101401-9381 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019381

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9381 1014019381

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Cross reference number

ZEXEL 101401-9381 1014019381

Zexel num

Bosch num

Firm num

Name

101401-9381

DPICO

INJECTION-PUMP ASSEMBLY
4D31T * Q

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-6220

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 11.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 69 68 70

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 69 68 70

Basic *

Fixing the lever *

Boost pressure kPa 93.3 93.3

Boost pressure mmHg 700 700

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1700 1700 1700

Average injection quantity mm3/st. 91 87 95

Fixing the lever *

Boost pressure kPa 93.3 93.3

Boost pressure mmHg 700 700

Injection quantity adjustment_05

Adjusting point C

Rack position R2-1.1

Pump speed r/min 680 680 680

Average injection quantity mm3/st. 35 31 39

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 67 67 72

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2-1.1

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R2(R1-0. 3)

Boost pressure kPa 80 73.3 80

Boost pressure mmHg 600 550 600

Timer adjustment

Pump speed r/min 1350--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1700

Advance angle deg. 4.5 4 5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=L36 BCL=1.1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(42deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at delivery) (2)Use the hole at R = aa (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd (non-injection rack position). Confirm non-injection. (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=(8)mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg

0000001501 ACTUATOR

(a) Screw (B) Nut Bolt c (d) Speed lever (e) Actuator shaft 1. Actuator adjustment procedure (1)Position the speed lever (d) in the idle position. (2)Set bolt (c) so that the clearance between the speed lever (d)'s pin and the actuator shaft (e) is approximately L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1 and read the rack position when negative pressure P1 is applied to the actuator. (5)Gradually loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Apply negative pressure several times and confirm that the lever (d) returns to the idle position at negative pressure '0.' (7)Confirm that rack position is R2 when negative pressure is P2.
----------
L1=2mm N1=500r/min P1=66.7kPa(500mmHg) N2=500r/min R1=9.1mm P2=66.7kPa(500mmHg) R2=9.1mm
----------

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=11deg
----------
a=(130deg)

Information:

TERMINATION DATE
31Dec2020
PROBLEM
Certain CB64B, CB13, CB66B, CB15, CB68B, CB16 Asphalt Compactors may have a problem with the DEF injector 459-7216. The internal seals within the DEF Injector may fail and allow DEF to leak into the injectors electrical connector housing. Once DEF enters the electrical housing and contacts the electrical pins a DEF Dosing current fault is triggered. This is usually accompanied by an external DEF leak being seen in and around the injectors electrical connector. DEF Dosing Unit/Actuator Diagnostic Trouble Codes (3361/3821) can be triggered which can lead to a system inducement.
AFFECTED PRODUCT
Model Identification Number
CB13 PWP00113-00218
CB15 M9400110-00144
CB16 HP500101-00105
CB64B C5600120, 122, 124, 126, 128, 133, 140, 143-144, 147-149, 151-152, 157, 159-161, 164, 166, 168-172, 175-177, 180-181, 192-193, 195, 199-201, 205, 208, 214-215, 222, 224, 233-234, 244, 247, 249, 254-255, 260, 268, 272, 275, 279, 283, 286, 289, 292-293, 297-299, 303, 307, 309, 312, 319, 321, 329-334, 337-338, 342-343, 348, 355-357, 360, 367, 370, 375-376, 378, 381, 386, 390, 394, 398-399, 401, 406, 408, 410, 412-414, 416, 419-420, 425-426, 429, 431, 433, 437-438
CB66B B6600101, 104, 106-108, 114, 116, 119-120, 124, 126-127, 129, 132, 135, 137-138, 141-144, 146-148, 150-151, 155, 157-158, 170-171, 179-180, 185-186, 189, 192-193, 203-204, 206-208, 211-212, 216, 229-232, 235-236, 238-240, 243-244, 246, 256, 261-263, 268, 271, 275, 278-279, 282, 284, 289-290, 292, 297-298, 305-306, 308-309, 313, 315-317
CB68B C6800101-00102, 105, 108-110, 114, 117-123, 126, 129, 131, 141, 146, 148
PARTS NEEDED
Qty
Part Number Description
1 4716029 MTG GP-INJECTOR
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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
If the engine software is not the latest version, update the Engine Software first.
If needed, update the engine software with the latest available in SIS Web.
For flash programming of the ECM software, refer to Troubleshooting "ECM Software - Install".
Ensure the appropriate steps have been followed when diagnosing a DEF injector failure. Refer to UENR0662.
If it is determined that replacement of DEF injector is required, refer to Disassembly and Assembly Manual - Diesel Exhaust Fluid Injector - Remove and Install.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.