101401-9480 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014019480

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-9480 1014019480

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Cross reference number

ZEXEL 101401-9480 1014019480

Zexel num

Bosch num

Firm num

Name

101401-9480

DPICO

INJECTION-PUMP ASSEMBLY
SH * 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 134424-1420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 4.4 4.35 4.45

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 10.4

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 59.5 57.9 61.1

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 350 350 350

Average injection quantity mm3/st. 12 10 14

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.4)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 59.5 58.5 60.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 43.6 39.6 47.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(10.4)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 51 47 55

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.35

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 77 73 81

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position (R1-0.1)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 58 54 62

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 85 105

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 4.5 4 5

Remarks
Measure the actual speed, stop

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
----------
T1=K35
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=36mm
----------
a=18deg+-5deg b=(38deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(130deg)

Information:

This Revised Service Letter replaces the 30May2018 Service Letter. Changes have been made to the Parts Needed.
TERMINATION DATE
31May2020
PROBLEM
The DEF injector can become plugged on certain D6N Track-Type Tractors. If the DEF injector becomes plugged it can lead to partial or full blockage of DEF flow.
AFFECTED PRODUCT
Model Identification Number
D6N LGP MG500195-00197, 199-1655
SGG00101-00214
D6N XL GB600100, 200-638
NJN00101-00156
PARTS NEEDED
Qty
Part Number Description
1 4182073 GASKET AS
1 4609257 INJECTOR AS-DEF
1 5457668 SFWR GP-A1000
1 BULK_COOLANT SEE OMM
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
DEF Injector Replacement ? Remove and Install:
Remove DEF injector and replace. Follow Disassembly and Assembly, UENR4079, for DEF Injector and Mounting - Remove and Install.
Update Engine Software:
Reflash the engine controller (ECM) with the software listed in the Parts Needed or latest available on SIS Web.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-5000 hrs,
37-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 100.0%
This is a 1.5-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.